Heritage System Evolution - ABB Group

© ABBSlide 1 -April 15, 2016


Heritage Evolution Stepwise Advant Evolution to 800xA

Glenn Törnkvist, BU CT Heritage Evolution 2016



800xAIt’s all about control

…security

...costs

… productivity



”It’s all about Control”Everyone has the same picture of what’s going on in the plant



800xA Collaboration Table

”It’s all about Control”Fully utilize Heritages Systems plant assets in 800xA

Alarm Analysis



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



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



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...



Stepwise Advant Evolution to 800xASix main areas

Operator Interface (HMI)

Engineering Tool

Communications network

Controllers

I/O’s

Drives



Stepwise Advant Evolution to 800xAEvolving the HMI - challenge


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.



Stepwise Advant Evolution to 800xAEvolving the HMI - solution


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.



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



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



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



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.



Stepwise Advant Evolution to 800xAEvolving the Communications System - challenge


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



Stepwise Advant Evolution to 800xAEvolving the Communications System - solution


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



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



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



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



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



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



Stepwise Advant Evolution to 800xAEngineering of AC 800M in Control Builder M

Function Designer for top down design



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



PAPI Sweden controller application software evolution Reference list September 2015



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



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



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



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.



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



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



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



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

Documents

Heritage System Evolution - ABB Group