Phil Coulton, Business Development Manager, MOD 300 MOD ... · MOD 300 Evolution Update User Group Houston 2014 Phil Coulton, Business Development Manager, MOD 300 . Phil Coulton

© ABB Group April 10, 2014 | Slide 1

MOD 300 Evolution Update User Group Houston 2014

Phil Coulton, Business Development Manager, MOD 300

Phil Coulton ABB Atlanta

MOD 300 Evolution Business Driver

40 years experience

Nuclear Industry UK

Oil & Gas Middle East 15 years

Engineering & Operations


MOD 300 Installed Base Sites 163 sites on July 24, 2013



Investment Protection ABB’s control systems are designed for continuous evolution. It is ABB’s goal to protect our customers’ intellectual investment (i.e. application software) beyond the lifecycles of the underlying platform products (i.e. hardware and software). ABB will not "Remove from Active Sale" any product or "family" of products until an equivalent replacement to those products is available. Once a product has been removed from active sale, ABB will continue to support the product for at least 10 years, although exceptions to this may occur if components or technologies needed are no longer available to ABB. Within this support period ABB will announce a “Last Buy” opportunity at least 12 months prior to the end of manufacturing (except in cases where there is a direct form, fit and function replacement). It is ABB’s intention to provide support for as long as there are significant customer needs after the "Manufacturing End" through field service, repair and by making replacement spares (new or refurbished modules) available.

Limited Classic Active Obsolete

Industry Leader in Lifecycle Management and Investment Protection

Your ABB automation system is designed for continuous evolution Always a path forward

Maximum investment protection

Underlying products are sustained by defined lifecycle phases Active until functional equivalent

Then, minimum 10 years support thru Classic and Limited phases

Documented Lifecycle Status

Manage system lifecycle costs through: Software Asset Management

Evolution Planning


Active

Product Life Cycle

Active (actively sold) until: Removal from Active Sales for new installations

Classic (manufactured and maintained) Last Buy until: Manufacturing End

Limited (serviced) Obsolete (normal support unavailable)

• AC460 Controller • S800 IO • CCF • TCL • TLL

Advant Station Software Released for Sale

Advant Station Hardware

X years Y years Limited Obsolete Classic

> 10 years

High Density I/O

MOD 300/Advant MOD 300/ PPB /800xA Continuous, upward, compatible improvements

HMI

Control

Engineering

1992+ 2001+ 1984+

Evolution through Enhancement

MOD 300 Multibus Console

AdvaCommand

MOD 300 Configurator

AdvaBuild (UNIX)

AdvaBuild (Windows)

Model A/B /SC Controllers

SC Controllers/ AC460

AC460

2005+

800xA CB, CDE, AdvaBuild 3.7

AC800M / AC460

800xA Operations, 800xA for MOD 300

PPB (Operate IT B)

Batch Produce IT 800xA Batch Management TCL Batch Batch 300

MOD 300 Advant OCS for MOD 300

Process Portals and MOD 300

Generation

Area

Tools Product Family Remarks

800xA Engineering The active version is 5.1 Rev A and FP1

•System and Graphic configuration

•Safety and Fieldbus applications

•MOD 300 CCF Library for AC 800M

AdvaBuild 3.7 The active software version is 3.7

AdvaBuild for Unix

Recommend evolution to AdvaBuild 3.6 (Window Server 2008)

Active

Classic

Limited

Obsolete

Product lifecycle status Engineering tools

Class: Consoles

Product Family Remarks

800xA Process Portal

800xA Operations is the eXtended Automation Operator Workplace for 800xA for MOD 300.

Process Portal B

Entered “classic” product lifecycle phase in Dec. 2008. Recommend evolution to 800xA Operations for Process Automation applications.

AdvaCommand

Advant Unix

Hardware Limited (2001) and Software Limited(2011)

Multibus Consoles .

Active

Classic

Limited

Obsolete

Product lifecycle status Operator consoles

Controller Product Family

Remarks

AC 800M Redundant PM861, PM864, PM866, PM891 Safety: PM865 PROFINET, FF, Device NET, Ethernet IP, IEC61850 Goose, …

CI862 TRIO interface

AC 460 TRIO, S100, and S800 MVI available, plus PLC’s

SC Controller Hardware is Obsolete. Software is Limited

Model B Controller

.

Active

Classic

Limited

Obsolete

Product lifecycle status Controllers

I/O Product Family Remarks

S800 I/O S800 I/O is configured using AdvaBuild and Control Builder

S100 I/O S100 I/O configured using AdvaBuild

MOD 300 Taylor Remote I/O (TRIO)

“Blocks” via ABB transitioned to “limited” in 2000. Genus 1 Blocks still Active from G-E.

TRIO on AC460 is ACTIVE. Recommend evolution to S800 I/O.

TRIO on AC800M is ACTIVE

Direct I/O Recommend evolution to the latest members of S800 I/O

High Density I/O Recommend evolution to the latest members of S800 I/O

Active

Classic

Limited

Obsolete

Product lifecycle status I/O subsystem

Communications Product Family

Remarks

eDCN Active. “DCN over Ethernet”

DCN Active. MOD 300 Distributed Communication Network, Token Ring protocol

Advant AC410 D/D, E/E, E/D

Active as Communications Gateway (D/D, E/E, and E/D)

Real Time Accelerator (External)

PU41x

(External RTA)

PU410 for eDCN

PU412 for DCN

Internal (PCI) RTAB

PU514A for eDCN

PU515A for DCN

Active

Classic

Limited

Obsolete

Product lifecycle status Control Networks/Communication Devices

eDCN

DCN

Product lifecycle status Production Management (Batch)

Class: Consoles

Product Family

Remarks

800xA Batch Management

800xA Batch Management is in the “active” phase of its product lifecycle.

ProduceIT Batch

Transitioned to “Classic” in December 2008. Recommend evolution to 800xA Batch Management.

Batch 300 Recommend evolution to 800xA Batch Management.

Active

Classic

Limited

Obsolete

Product lifecycle status Information Management (History)

Class: Consoles

Product Family Remarks

800xA Information Manager

IM is in the “active” phase of its product lifecycle. Can inter-operate with AdvaInform V2 & V3 (consolidation node).

AdvaInform V3 Enterprise Historian

Transitioned to “Classic” in April 2008. Recommend evolution to 800xA IM. Process Portal B

AdvaInform V2 – (UNIX)

Transitioned to “Classic” in May 2005. Recommend evolution to 800xA IM.

History (Multibus) Transitioned to “Limited” in April 2001. Recommend evolution to 800xA IM.

Active

Classic

Limited

Obsolete

MOD 300 Controller: AC460

High Performance

Faster CPU

More user memory

Increased Security

1:1 redundancy

Redundant I/O options

Uses Existing Control Configurations

S800 I/O

S100 (redundant)

TRIO

Open Architecture

PLC and third-party interfaces

Profibus

DCN or eDCN connection

Investigation underway for potential development of new control modules with higher performance and more memory.

Increased value for customers

Long term sustainability

AC460 I/O

S800 Remote I/O

Small Footprint

Wide Range of I/O Modules Types, Including Intrinsically Safe

Redundant Communications

S100 Redundant I/O

Redundancy to the I/O: analog and digital

Supports: Extended Over range (EOVR), Output Hold (OH), and Warm start (Warm)

Re-engineered for long term manufacturability Surface Mount Technology for

Higher Reliability and Extended Life-cycle


Rich Functionality

Long term sustainability

TRIO

Controller interface modules are Active

AC460 MVI

AC800M CEX

ABB commits to support TRIO as long as the GE maintains Form, Fit and Function

GE continues to manufacture GENIUS I/O (TRIO) (they have retracted their prior statement about a lifecycle change)



IndustrialIT System 800xA for MOD 300

The need to evolve.

© ABB Group Month DD, Year | Slide 18

1984

1988

1992

1996

2000

StationStation

S800 I/O

1994

MOD 300 DCSSC Controller w/ TRIO

MOD 300 DCSw/ Model B Controller

AC400 Series

Evolution through

Enhancement

Evolution without

Obsolescence

System 800xA2004

Control system evolution is: • The continuous process of updating

systems to current technologies so manufacturing operations remain

competitive in today’s global environment .

• An incremental process. • Based upon using your existing

installation as the foundation for change • Typically a systematic, on-going effort,

with a step-by-step approach is recommended.

Evolution Process Site Audit

System Overview

HMI Details

Controller Details

CPU Loading

Memory Utilization

Applications Running

EH Data

Number of Logs Sample Rates

Batch Data

Licensing Info


Evolution Steps

Site Audit Report

Evolution Report


Existing Control System - Solution Area

Notes

ABB

APP

Date: 9-11-06xxxx-xxxxCust. Ordr. No.

Sheet 1 of 1

Size B Rev. 1Drawing No.Cust:Scale: None

A

B

C

D

A

B

C

D

1 2 3 4 5

Revisions:

6 7 8

1 2 3 4 5 6 7 8

Dr. Phil Coutlon

Title:

ASIS June 2012EtherNetEtherNet – Fiber OpticRemote I/O

AC

460

CS

S 2

00

AC

460

CS

S 7

00

Futu

re C

SS

1100

OS/ES ASR 01

OSASR 02

OSASR 03

OSASR 04

OSASR 06

OSASR 05

Eng PC

Eng PC

IMSASR 08

OPC Server1100 Notes

1) All Unix Stations support 3 Clients.2) AdvaBuild ver 2.7/43) AdvaCommand ver 1.7/2

Risks of not moving Forward.


Single Point Failure in HMI’s could result in HMI being non recoverable.

ABB no longer supplies these items.

Ebay or equivalent is the only option, condition unknown.

Production Downtime Cost versus Project Cost.

Unplanned failure could impact production.

XXXX has experienced 2 hard drive failures per year for the last two years. RTA (Interface between HMI and Controllers) boards are only available only as refurbished units and the Unix station parts are scarce, used and 15 years old.

Evolution Plan


Notes

ABB

APP

Date: 06- 16- 12xxxx-xxxxCust. Ordr. No.

Sheet 1 of 1

Size B Rev. 2.0Drawing No.Cust:Scale: None

A

B

C

D

A

B

C

D

1 2 3 4 5 6 7 8

1 2 3 4 5 6 7 8

ASRCPhase 1 2013

Option 2Dr. Phil Coutlon

Title:

AC

460

CS

S 2

00

AC

460

CS

S 7

00

CS

S10

00

OSASR 02

Advacmnd 1.9

OSASR 06

Advacmnd 1.9

OPC Server 1100 Existing

Notes1) 1 Environment2) ASR 02, ASR 06 remain backup for x Months.

300 Tags 15 Graphics

MOD 300 Distributed Communications Network

1 2

3

AdvaBuild v 3.7Redundant Connectivity Servers

Primary Redundant Connectivity ServersRedundant Connectivity Servers

Primary Redundant Connectivity ServersRedundant Aspect Servers

Primary Aspect Servers

Primary Domain Controller

Redundant Domain Controller

4 5

6 9

7 8

10 11

12

13 14

15

16 17

18

KVM

IMS 6500 Tags

Eng 1 Opr

Eng 2 Opr

Eng 3 Opr

Eng 4 Opr

19

21

20 22

24

23

Evolution Plan Phase 1


Notes

ABB

APP


Sheet 1 of 1


A

B

C

D

A

B

C

D

1 2 3 4 5 6 7 8

1 2 3 4 5 6 7 8

ASRCPhase 1 2013


Title:

AC

460

CS

S 2

00

AC

460

CS

S 7

00

CS

S10

00

OSASR 02

Advacmnd 1.9

OSASR 06

Advacmnd 1.9





1 2

3







4 5

6 9

7 8

10 11

12

13 14

15

16 17

18

KVM

IMS 6500 Tags

Eng 1 Opr

Eng 2 Opr

Eng 3 Opr

Eng 4 Opr

19

21

20 22

24

23

Update ES

Evolution Plan Phase 2


Notes

ABB

APP


Sheet 1 of 1


A

B

C

D

A

B

C

D

1 2 3 4 5 6 7 8

1 2 3 4 5 6 7 8

ASRCPhase 1 2013


Title:

AC

460

CS

S 2

00

AC

460

CS

S 7

00

CS

S10

00

OSASR 02

Advacmnd 1.9

OSASR 06

Advacmnd 1.9





1 2

3







4 5

6 9

7 8

10 11

12

13 14

15

16 17

18

KVM

IMS 6500 Tags

Eng 1 Opr

Eng 2 Opr

Eng 3 Opr

Eng 4 Opr

19

21

20 22

24

23

Remove Unix Boxes replace with 800 xA

Evolution Plan Phase 3 Power House Addition.


Notes

ABB

APP


Sheet 1 of 1


A

B

C

D

A

B

C

D

1 2 3 4 5 6 7 8

1 2 3 4 5 6 7 8

ASRCPhase 1 2013


Title:

AC

460

CS

S 2

00

AC

460

CS

S 7

00

CS

S10

00

OSASR 02

Advacmnd 1.9

OSASR 06

Advacmnd 1.9





1 2

3







4 5

6 9

7 8

10 11

12

13 14

15

16 17

18

KVM

IMS 6500 Tags

Eng 1 Opr

Eng 2 Opr

Eng 3 Opr

Eng 4 Opr

19

21

20 22

24

23

Power House Addition Savings approx 250K

Consolidate Into CS 1100

a. 200 Ain b. 45 Aout c. 300 DI d. 100 DO e. 50 Graphics

Power House Incorporation into Existing Subsystem Savings


By utilizing existing existing Contoller Sub-System.

Hardware (Cabinets, Power Supplies labor cost, )

50K

Utilize the same ES,

97K Utilize the 800xA Components. Historian, Domain Controller etc.

100K

Total Savings 200K – 250K

Time Line and Impact on Production


Yr 1 Upgrade ES.

Executed at ABB

Downtime 8 hrs

Risk Low.

Phase 1 Phase 2

Upgrade Unix to 800xA

ABB/xxxx Project

Executed off site

Extensive offsite testing

Downtime Zero.

Risk Low.

Phase 3

Power House Addition.

Off site execution

Extensive Off Site Testing

Downtime 3 Days

Field wiring will extend this time.

Risk Low

Documents

Phil Coulton, Business Development Manager, MOD 300 MOD ... · MOD 300 Evolution Update User Group Houston 2014 Phil Coulton, Business Development Manager, MOD 300 . Phil Coulton