SYMPHONY/DCI Enhanced with IndustrialIT

The Enterprise Management & Control Systemfor Optimizing Process & Business Operations

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Within ABB’s new family of integratedsoftware and hardware solutions –collectively known as Industrial IT – theABB SYMPHONY™ DCI Enterprise Manage-ment and Control System positions customersto optimize process, plant and enterpriseoperations. While reaping the benefits of theinnovative, enhanced Industrial IT strategy,customers will retain both the processsecurity and the value of their new orexisting SYMPHONY DCI system.

SYMPHONY DCI enhances the real-timesharing of knowledge between related,but divergent, enterprise operations. Fullyequipped with an integrated set ofdecision-making tools, Industrial IT makesit possible for real-time information to beshared – and its value compounded –throughout an organization. The result isbetter and faster decisions that optimizecompany assets, whether people, rawmaterial, process, or infrastructure.

Open Architecture forSeamless IntegrationIndustrial IT applications are designed tobe used as stand-alone or integrated solutions,enabling the flexibility to implement therequired functions today and the agilityto add on as needs evolve. ABB’s diligentuse of open standards simplifies the taskof interfacing with existing automationand information systems, while the provenSYMPHONY DCI progression ensures anadditional layer of established investmentprotection.

The Evolution Continues…Industrial IT is the latest installment on a20-year commitment that ABB has honoredwith its DCS users. The company’s pledgeof Evolution through Enhancement ensuresthat future advances in system technologieswill not compromise the customer’s currentinvestments. While other vendors may talkabout investment protection, ABB’s provenprogram is truly unique in the industry. Alltold, from the introduction of DCI-4000 in1979, through each of the evolution steps ofDCI-5000, DCI System Six and SYMPHONYDCI, to the introduction of Industrial IT, thisfamily of systems represents a significantcontiguous installed base of process automa-tion systems in the world – an installed baseexceeding USD $1 billion!

A Global LeaderToday, Evolution through Enhancementhas expanded to include the latest productsand services from the world’s largest auto-mation supplier; including instrumentation,analytical devices, meters, robotics, drives,motors, machines, manufacturing executionsystems, and control products and systems.Backed by common Industrial IT technologyand industry specific expertise, ABB’s automa-tion portfolio provides the seamless linkbetween process and business managementto deliver knowledge-based solutions.

Reaching New Levelsof Productivity

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Making real-time business decisions toprevent or limit process upsets requires aconsistent infrastructure for data, operations,configuration, and maintenance across theentire enterprise. The foundation of thisconsistent infrastructure is ABB’s AspectObject™ technology provided by the AspectIntegrator Platform (AIP) component. EveryIndustrial IT software product is based uponthe AIP component. Symphony DCI fullyparticipates in an integrated Industrial IT

Two Decades of Enhancementsenvironment by leveraging the full powerof the Aspect Object technology by employ-ing an open, enterprisewide architecture thatsupports a seamless communications fabricto every level of control – from field I/O toplantwide and multi-plant systems. SYMPHONYDCI essential security and proven availabilityat the control level are integrated withenterprise network strategies for totalenterprise communication.

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The scalable SYMPHONY DCI architectureallows for easy integration of ABB IndustrialIT components, such as Operate IT, ProduceIT, Inform IT, and Optimize IT. In addition,non-traditional DCS functional areas, suchas field device management and PLC con-trols, simply “plug-and-produce” in theSYMPHONY DCI architecture via other ABBIndustrial IT components, such as EngineerIT and Control IT.

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ABB’s Industrial IT with SYMPHONY DCIsolutions reach beyond the traditionalboundaries of distributed control systemsto support the platform, application andprofessional service needs of total enterprisemanagement and control.

SYMPHONY DCI’s multi-tiered span ofcontrol provides a secure foundation withrobust, but flexible, base level regulatoryand sequence control. Solutions continuethrough the full range of higher level man-agement and advanced control functions toinclude: flexible batch production manage-ment, maintenance management, simulation,historian, and network management. Theintegration of these powerful features isachieved through SYMPHONY DCI’s inte-grated “plant-centric” architecture. Embod-ied in the principles of open, real-time

networking, the SYMPHONY DCI architec-ture provides a scalable communicationsfabric that spans and integrates loop, unit,area, plant, and interplant controls.

Industrial IT with SYMPHONY DCI dramati-cally improves enterprisewide productivitythrough four powerful, integrated classesof products:

Harmony Series Area Management andControl Products – a comprehensive set oftraditional process, regulatory, sequence andbatch control services and I/O interfaces

Composer Series System Engineering Tools –an integrated suite of engineering andmaintenance tools designed to supportthe complete automation project, includingnetwork administration, configurationmanagement, library management, commis-sioning, and operation

Operate IT/Conductor Series HumanSystem Interfaces – a range of consoleproducts for accessing and viewing datafrom multiple operating environments,from process control and I/O to plantand enterprise information

Industrial IT Plant Optimization andInformation Management Solutions – apowerful suite of products and services forplant management and control focused onincreasing asset utilization and on optimalmanagement of plant capacity

Powerful Toolsfor Enterprise Management and Control

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Plant Optimization& Management

Engineering, Operation& Maintenance Tools

Human SystemInterfaces

Area Management& Control

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Control Products

The Harmony DCU is a proven, robust, andreliable platform that integrates microproces-sor-based controllers and I/O boards withflexible control software to handle a widerange of applications. Thirty-two bit pro-cessing, coupled with modular scalability,make the Harmony DCU a powerful andversatile performer.

The Harmony DCU is available as a rack-mounted frame assembly that houses keysystem components, including the controllerand local frame mounted I/O modules. Thecontroller board also supports redundantEthernet™ TCP/IP network communicationsfor interfacing with other controllers andcomputer applications. A modular powersystem provides efficient, replaceable powerfor both control and I/O functions. TheHarmony DCU is designed with one-to-oneselective redundancy as an integral concept,providing the control system user with thehighest level of availability.

The Controlware II software used by theHarmony DCU features an extensive libraryof over 200 pre-defined advanced controlalgorithms and user-definable functions.

These functions provide the power to easilyconfigure complex control strategies to fitany control application including continu-ous, sequential, batch, and advanced con-trol. Controlware II also supports CCL, apowerful structured text language forimplementing advanced strategies for batchand multi-variable control. The multifacetedHarmony DCU communicates simulta-neously with numerous serial device com-munication protocols as well as Profibus DP.

The Harmony DCU accepts a wide variety ofI/O from local frame mounted and remotemodular form factor options. Both formfactors support signal conditioning capabil-ity, ranging from standard analog and digitalI/O to specialty I/O like pulse. Framemounted redundant I/O uses commonfield-wired connections per channel andprovides a high level of I/O availability.Modular I/O, located as far as 2 miles away,communicates to the DCU via redundantProfibus DP network trunk lines at up to12 Mbaud using S800 I/O. S900 I/O can beused for hazardous applications.

Symphony DCI’s control products supportABB’s Evolution through Enhancementstrategy by providing backward compatibil-ity with DCU3200 control processors withthe ability to fully execute their controlstrategies. Tools to migrate previous genera-tion DCI-4000 and DCI-5000 Controlwaresoftware to Controlware II enable costeffective migration towards the HarmonyDCU. The addition of Industrial IT compo-nents, when used for non-traditional DCSplant control applications such as AC800 formotor controls and remote terminal unit(RTU) operations, complement theSymphony DCI system. Data exchangebetween these areas of control is facilitatedat both the controller and operator interfacelevel through an OPC data link connection.

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Engineering ToolsTo ensure that the SYMPHONY DCI systemcan be efficiently configured and main-tained, ABB has designed a comprehensivesuite of Composer Series tools supplied in aConfiguration Toolkit (CTK). The toolkitprovides a visual environment for easyconfiguration of control system strategies,global configuration databases and operatorinterface graphics, and manage systemlibraries of reusable software components.

The working environment of ComposerCTK simplifies the configuration andmaintenance of SYMPHONY DCI systemsby providing a standard Microsoft®

Windows environment, which enablesthe user to easily explore the currentsystem configuration and configure newelements. The use of a common system,or project-wide database, eliminates theduplication of data entry and automatesthe configuration of many interrelated tasks.Composer CTK also provides completesystem documentation of the “as installed”and “commissioned” systems.

Composer CTK provides two key featuresfor system configuration. By using a multiuserclient/server architecture, they allow configu-ration information to be accessed, createdand modified simultaneously by differentusers. Composer CTK integrated explorerpresents a single, unified view of theSYMPHONY DCI system architecture, andallows the appropriate tool for each systemelement to be invoked directly from thatelement.

Consistent with ABB’s commitment toEvolution through Enhancement, theComposer Series is designed to integratewith ABB’s Industrial IT products, whilemaintaining compatibility with SYMPHONYDCI systems. Planned integration with othercomponents of ABB’s Engineer IT suite willallow Composer CTK to further enhancedesign and maintenance efficienciesthroughout the enterprise.

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Operator Interface

Conductor SeriesConductor provides an incremental seriesof platforms for operator interface thatcomplement the inherent functionality ofthe control system with the basic suite ofoperator directed features and functions.These versatile features and functions areergonomically designed to facilitate processmonitoring, control, fault mitigation, andoptimization. They provide system userswith expanded dynamic access to allplant-wide or enterprise-wide informationthrough open system connectivity.

For DCI Systems, two Conductor operatorinterfaces are available: Conductor NT andConductor UX. Both of these productsprovide the same managed multi-windowsuser experience with the only notabledifference that Conductor NT is Windowsbased while Conductor UX is Unix based.These reliable yet flexible operator interfaceshave a proven track record for providingsecure and up-to-date information for plantoperations, maintenance, and managementaccess. Meeting the traditional needs forplant automation control, Conductor

supports hierarchical displays for summary,group, and point displays, custom processgraphics displays, trend displays, alarmreview displays, event history displays,automatically generated system statusdisplays, spreadsheet style reporting, andopen data access via DDE with @aGlance.

Conductor also provides for the highest inprocess availability with automatic redun-dancy built-in when used with the DCIsystem. Any change made in one server canautomatically be synchronized with another.If one server should fail, the other is alreadyin operation and able to automatically takeover the management of those clients thatwere attached to the faulted server.

In an era where network accessibility canpotentially lead to unauthorized access, it iscritical that a control system provide thenecessary tools to mitigate such access.Conductor, with the Harmony DCU, com-bine to provide a flexible yet intuitivesecurity system. Layered within Conductoris a nine level security system focusedtowards process automation user accountsfor Operators, Engineers, and Supervisors.Users can log-in and log-out of Conductorwhile maintaining their view of the plantoperation. What truly makes this securitysystem unique is that every attribute in theHarmony DCU such as a set-point, a con-troller operation mode, or a start command,is associated to one of the nine level secu-rity accounts. Even if an unauthorized usergets access on the Ethernet, theHarmony DCU provides a last line of de-fense by validating the user access levelagainst each attribute access level. Onlyusers with appropriate access can effect achange to the controller attributes.

Included within Conductor is a data histo-rian that collects and stores data for use byit’s own trends and reports, and for externaldata access. This historian provides a cost

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Operators gainthe advantage ofsingle-click accessto information-richaspect views…

ERP interfacesPDF technicaldocumentation

Data tags

Worddocumentation

CADspecifications

effective solution for typical operator inter-face needs without demanding the purchaseof a high-end historian. The historian cancollect data for periods of weeks or monthsand provides a manual or scheduledarchiving function. Automatic backfill ofdata takes place when an offline historianrecovers and is brought back online.

With the flexibility and power of Conductor,it is no wonder that users today alreadyunderstand that they have a system that isenhanced by Industrial IT.

Operate IT Process PortalProcess Portal is a feature rich web-enabledoperator interface available today for manyABB control systems that is also planned foruse with DCI Systems in the near future.Designed as a native Windows basedproduct, Process Portal provides a managedwindows workplace supporting its userswith intuitive navigation and compatibleintegration with other ABBand third-party web enabledapplications, allowing usersto efficiently access andmonitor information flowthrough the control system,the process, the plant, andthe entire enterprise. As partof an open system, ProcessPortal embraces OPCTM toprovide a standard interfacemethod with third partydevices, and incorporatesOPC client connectivity.

Process Portal supports thefull spectrum of plant andenterprise personnel needsincluding graphical userinterface, process datacollection, storage andanalysis tools, an advancedalarm management system, acomprehensive historian, and

an advanced reporting package. Throughthe use of ABB’s unique Aspect ObjectTM

technology, Process Portal provides inte-grated information access and sharing,intuitive navigation and efficient engineer-ing. Aspect Objects represent a physical orlogical part of the automation installation,such as a valve or pump, but also combina-tions of them. All information, or aspects,belonging to those objects is configuredonce and is consistently available to theoperator by a right mouse click no matterwhere or how the aspect object is repre-sented in a graphic, in a trend, in an alarmlist, or in a thirdparty applicationlike a Worddocument.

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Data Management

To achieve true enterprise automation,Industrial IT with SYMPHONY DCI compo-nents go beyond traditional process controlto tightly integrate both control and manage-ment functions from the plant floor to theexecutive staff. To achieve this increasedspan of control, ABB offers a suite of plantmanagement and control products, rangingfrom plant information management to plantoptimization applications.

Industrial IT plant management and controlproducts improve enterprise productivity by:

• Providing secure, tightly integrated baseregulatory and sequential controls

• Scaling advanced control across a rangeof technologies

• Facilitating process information propaga-tion throughout the enterprise

• Providing for both adaptive and predictivedecision support practices

• Supporting E-commerce and B2B strate-gies with real-time enterprise data

• Imparting protected web access when andwhere appropriate

Advanced Control for IncreasedEfficiencyAdvanced control packages provide opti-mum production management solutions.From multi-variable control applications atthe controller level to enterprise spanningPavilion solutions, Industrial IT delivers afoundation for advanced control techniquesin real-time. Backed by industry specificexperience and know-how, Industrial ITadvanced control applications designed toinsure that plants will operate more efficiently,profitably and competitively.

Inform ITInform IT is the key element of informationmanagement. Information management isessential for understanding asset perfor-mance and designing procedures for opti-mizing assets over their life cycles. WithInform IT, users increase engineering effi-ciency by working in a flexible distributedenvironment offering both high data securityand remote access. The platform providestools to capture, archive, model, and analyzedata to create informative reports and tomake better decisions.

ABB provides industry specific extensions ofInform IT – such as profile and contourvisualization for paper and flat sheet pro-cessing – as well as other applications wherequality gauging systems are required.

Process Information Web Server (PIWS)supports controlled intranet informationaccess across the enterprise. PIWS can assistcustomers who have a constant need forprocess information and status as well ascustomers with temporary requirements.

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Optimize ITOptimize IT’s advanced optimizationsolutions address the need for real-timeeconomic optimization in the multi-period,multi-plant enterprise.

Asset Optimization includes integration offield instruments to the control system viafieldbus protocols, maintenance triggers,interfaces with maintenance managementsystems, documentation management, andaudit trails

Process Optimization provides the meansto create and manage process models thathave been optimized using a range ofsolutions. This allows users to addressyield accounting, waste, safety, regulatorycompliance, and economic issues

Dynamic Simulation and Training assistsoperator training and certification and aidswith design validations

Supply Chain Optimization includes inte-grated planning, scheduling and utilizationalgorithms and decision tools for productionof specified component quality and quantityto support E-commerce requirements

ChemFlexChemFlex is a flexible batch automationand management application for use withConductor series consoles with DCI systemsthat supports recipe creation / editing,equipment database creation / editing,batch scheduling, unit operations monitor-ing, and batch reporting. Based upon theS 88 standard and its definitions, ChemFlexsupports the visual creation of recipes basedon procedures that are linked to phasessupported by equipment defined in theequipment database. The visual depictionof the recipe is then used to monitor the

recipe as it progresses from one procedureto the next. Batch records are then collectedbased upon the unique Batch ID suppliedwhen the batch was scheduled. This datacan then be accessed for Conductor reportsor by external applications through DDE via@aGlance.

Produce ITProduce IT Batch provides batch productionmanagement solutions available today formany ABB control systemsthat is also planned for usewith DCI Systems in thenear future. Produce ITBatch delivers unsurpassedbatch-to-batch consistency,quality and productivity.These measurable resultsare achieved throughunmatched level andscope of batch controlintegrated with scheduling,electronic batch records,operator interface, history,and controllers. Whether a process ismanual, automated, or both, Produce ITbatch offers solutions for stand-aloneenvironments or for integrated operationwith ERP, DCS, etc.

Linking Process Control withEnterprise ManagementEnterprise Production Management Softwarecapabilities permit facilities to link processcontrol with enterprise management andother information systems to support regula-tory compliance and collaborative com-merce, facilitate decision-making and permitoptimal capacity utilization and supply chainmanagement. Offerings are available forboth Windows and UNIX platforms.

These Industrial IT optimization technologiescan be added to a customer’s SYMPHONYDCI system today, helping to achieve thecompetitive advantage necessary to operatein the dynamic global marketplace. ABBleverages its expertise in various industrysegments to offer customized optimizationapplications and products to power utilities,water and wastewater, pulp and paper,chemical processing, hydrocarbon processing,and other industrial markets.

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Global Support & Services

As a leading global provider of industrialasset and optimization services for powerand automation systems, ABB maintains aunique position to offer innovative anddiverse solutions for improved facilityperformance and effective maintenancesystems management. With an unparalleledscope of automation products, systems andservices, we provide performance-basedservice packages that increase production,reduce maintenance costs and improvereturn on existing assets.

Asset Management ServicesABB Asset Management Services movebeyond a cost-cutting approach, offeringcustomized performance-based servicesfocused on a specific need, an entire assetclassification or complete plant maintenanceresponsibility. Optimizing asset managementthrough outsourcing designed to deliverimproved operation and maintenanceeffectiveness, helps to deliver a lighterbalance sheet and increased cash flow,while providing maximum value andprofitability.

Asset Management ServicesConsulting Services

- Plant Performance Benchmarking- Performance Improvement Delivery- Cultural Change Management- Sustainable Maintenance Excellence- Shutdown Excellence- Safety, Health & Environmental Excellence

Total Equipment Management

- Motor Condition Monitoring- Drive Management- Rotating Machine Management- Instrumentation Management- Control Systems Management

ABB Full Service

- ABB Full Service™ Partnership Agreements- Single Shutdown Contracts- Multiple Shutdown Partnership Agreements

Product And SystemServicesA wide variety of services are availablelocally providing total system as well astailored user support. From completemanagement services to just-in-time techni-cal support, ABB offers unequalled servicesfor power and automation systems. Ourdiverse industry and application knowledgeacquired through a strong global presencecan benefit your operation through im-proved overall performance, increaseduptime and reduced costs.

Product and System ServicesCustomer Support Services

- Hardware/Software- Contract & Demand- Web, On-line & Remote Services- Telephone Services- Upgrades, Expansions & Modifications

Training Services

- ABB Product Training- Process & Application Training- General Technology Training- Training Contracts- Training Assessment Programs

Parts & Repair Services

- Parts Services- Reconditioning & Repair Services- Version Management- Legacy Product Support- Parts Management Support

Application Services

- Installation & Commissioning- Product Application Services- Product Environmental

Adaptation Support- Process Application

Services- Product Migration

Services

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Evolution ServicesStepUpStepUp Programs provide a cost effectivemeans to migrate to the latest ABB productsand help position your automation systemfor new technology as it becomes available.

This allows you to continuously evolve yoursystem to higher levels of control, operations,information management, and connectivity.

SoftCareThe SoftCare software management programcontinuously provides you with immediateaccess to the latest productivity enablingsoftware. In keeping your software current,SoftCare positions you for the constantlychanging industry and IT standards byproviding constant enhancements, betterintegration, and more efficient support.

Conversion ServicesIn development of new products, it hasalways been ABB’s philosophy and commit-ment to provide an evolution path for theinstalled base. We continue with that commit-ment by providing conversion and interfaceservices that assist in graceful migration.

These services help simplify the evolutionprocess, reduce engineering cost, reduceinstallation time, and reduce risk.

ABB Inc.29801 Euclid AvenueWickliffe, Ohio 44092Phone: +1 440 585-8500Fax: +1 440 585 8756www.abb.com/controlsystems

Copyright © 2003 by ABB Inc. All rights to trademarks reside with their respective owners.

Specifications subject to change without notice. Pictures, schematics and other graphics contained hereinare published for illustration purposes only and do not represent product configurations or functionality. Userdocumentation accompanying the product is the exclusive source for functionality descriptions.

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ABB GmbHDudenstraße 44-46, D-68167Mannheim, GermanyPhone: +49 (0) 1805 266 776Fax: +49 (0) 1805 776 329www.abb.com/controlsystems

ABB ABSE-721 59 Västeras, SwedenPhone: +46 (0) 21 34 2000Fax: +46 (0) 21 13 78 45www.abb.com/controlsystems

For additional information,visit us on the Internet at www.abb.com/controlsystems