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Stages of a Global Success

Symphony Melody goes IndustrialIT

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Proven, open, and future-oriented are the mostappropriate adjectives to describe SymphonyMelody, ABB’s modern IndustrialIT process con-trol system. The system structure and the com-ponents of Melody are designed in such a waythat they meet the requirements of differentmarkets and applications in the best possibleway.Using the comprehensive functionality, it is easyto adapt the process control system to theautomation tasks at hand, while the scalableredundancy guarantees maximum reliability.The powerful controllers are distributed hubs ofthe automation. These are networked via aredundant bus system. In addition, they consti-tute the links to input/output modules, fieldbussystems, as well as higher-level engineeringand operator stations in the control room.

Use what you haveto get what you need

The “Composer” tool, is a multi-user engineer-ing tool offering functions that efficiently sup-port the economical operation of a plantthroughout its entire life cycle, that is, fromplanning and design to commissioning, opera-tion, and maintenance.

Proven …

There are already more than 1000 installationsof Melody in various markets and fields of ap-plication all over the world.The wide range of Melody references includespower stations, water and sewage processing,pharmaceuticals, petrochemicals, metal andcement industries, sugar manufacturing, andmany more. This brochure presents a selectionof industry applications showing the impressiveperformance of Melody.

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… Future-oriented

“Use what you have to get what you need”.Melody has proven its value on numerous occa-sions, with the result that customers from allsorts of industries trust in automation solutionswith Melody. This is particularly the case whendealing with large, distributed plants. Todaymore and more products of the Industrial ITportfolio are integrated into Melody, and thisnumber is set to grow even further in the future.That's why your current plant is well equippedto adapt to new opportunities and marketrequirements. Melody perfectly protects yourinvestments.

... Open …

In the field area, Melody gives you freedom ofchoice between a centralized and a distributed system architecture. Thanks to the fact that itconsistently follows fieldbus and device stan-dards, Melody seamlessly integrates intelligentfieldbus stations and devices. These are, forexample, PROFIBUS and FDT/DTM.The control and management level offers pow-erful operation functions through the integrationof the OperateIT Process Portal human systeminterface, the integrated ProduceIT Batch pack-age for procedural control, and other manufac-turing execution systems such as InformIT andOptimizeIT.

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Melody – success in numerousindustries all over the world

Germany – spotlight on the largest Profibusinstallation in the world

Thyssen Krupp Stahl AG/Carbonaria GmbH &Co. KG awarded ABB the contract to providethe entire control system for a new coking plantnear Duisburg. The Control IT CMC70 control-ler module is used for the basic automation ofthe plant, while the Operate IT Process Portalwith 30 operator stations and another 68screens constitutes the engineering and opera-tor level. The plant’s field devices are connect-ed to the control system directly via ProfibusDP/PA and are configured and parameterizedusing Composer with embedded FDT/DTM

technology. This has around 25,000 I/Os, mak-ing it the world’s largest Profibus installation inthe industry.Thyssen Krupp had particularly stringent require-ments related to the design of the control tech-nology. Also in this case, the customer wasconvinced of ABB's technology because of: »The end-to-end networking at all automation

levels»The seamless dataflow from the manufactur-

ing execution system to the individual sensor

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China – generating and utilizing potential savings

Melody has also demonstrated its advantagesas a power station control system at China’slargest power station site in Shajiao, locatedbetween Canton and Hong Kong.Having installed Melody in the first block as earlyas 1998, the company has now installed thesystem also in its third block. In this process,the system fieldbus for connecting the MelodyI/O modules was wired to the field in a star-topology, allowing the sensors and actuators tobe connected remotely in small on-site cabinets,as is the case for a remote I/O.

It was possible to:

»Save a considerable amount of money forthe cabling

»Fully utilize the advantages of the Melody I/Omodules

In addition, thanks to the user-friendly handlingof the Composer engineering tool, the Chinesewere able to carry out the majority of the engi-neering and commissioning tasks themselves.

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South Africa – upgrading to state-of-the-art technology

The Petro SA refinery in South Africa was dueto renew its technical systems. In this context,the company teamed up with ABB over thepast two years to add Melody controllers to itsexisting Contronic P system, thus upgrading itstechnology to the state of the art. At Petro SA,one of the country’s largest refineries, the newuser interface being used is the Operate ITProcess Portal. Consequently, the implementa-tion of Process Portal – together with Melodystations – was also installed in a newly builtsection of the plant.Especially for large facilities such as a refinery,which has special requirements related to se-curity and availability, Melody offers particular

advantages:»High availability thanks to full redundancy at

all levels» ”Multi-User Engineering” for efficient engineer-

ing and commissioning with several users» Intrinsically safe I/O modules

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Switzerland – the recipe for reliable recipe processing

Teranol AG, located in the Swiss town of Lalden,produces vitamins, carotins, and other relatedsubstances for flavorings. Here, several Melodystations manage the production of up to 10recipes running in parallel. Melody, with its inte-grated recipe processing functionality, is espe-cially suited for the complex structures contain-ing up to 8 modes for each basic function.After all, batch-oriented production processesare particularly good examples of an areawhere you can completely rely on Melody ad-vantages such as:

»Easy recipe creation with plausibility checking»Consistently easy to operate, from recipe to

tag»Automatic recipe execution» Recipe management» Flexible plant use» Comprehensive documentation options

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This makes Herningsvaerket a prime exampleof how the Melody control system has particu-lar advantages for power stations:

» High efficiency» High availability» Built-in security functions

Denmark – quick revamp for cozy warmth

Melody was also the power station control sys-tem chosen to upgrade the boiler automation inthe Danish Herningsvaerket power station. Oneof the requirements here was that the renewalhad to be completed within a "non heating"period of just 10 weeks. The primary reasonwhy this could be achieved was due to the factthat interfaces existed between all parts of thesystem, allowing the plant to be tested “cold”.The power station could therefore be startedup again particularly quickly and hassle-free.Two operator terminals can now be used in Her-ningsvaerket to control and monitor the entireoperation of the power stations: with functionsfor controlling the fail-safe burner, protectingthe boiler, as well as controlling and protectingthe turbines being integrated into just one sys-tem.

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Brazil – simplified operation of coupled systems

In a fertilizer factory in Brazil, Symphony Melo-dy is deployed to couple the signals of 20 on-site systems and create a uniform interface foroperating the plant. In this case, the customer’sdecision to implement the ABB system wasprimarily based on functions such as the fol-lowing:

» Complex batch processing» Full redundancy» Straightforward integration of field devices» Easy connection to various fieldbuses»A central engineering database that also

allows partial deliveries

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United Arab Emirates – turning sea water into fresh water

Melody is also used in two large plants in theUnited Arab Emirates. In the Al Taweelah seawater desalination plant, around 50 km to thenorth-east of Abu Dhabi, 227,000 cubic metersof clean drinking water is obtained from seawater each day with the help of Melody.The second project involves a power stationand a desalination plant in Umm al Nar West,around 15 km to the east of Abu Dhabi, sup-plying the capital of the United Arab Emirateswith both electricity and water. Here, a colossal465,000 cubic meters of drinking water is pro-cessed each day – an amount that would coverthe daily drinking water requirements for about3.5 million people in Germany.

Both plants have been expanded by usingMelody. The formerly used control level hasbeen replaced with a modern engineering andoperator system. Melody controllers and I/Odevices have been added to the process level.The advantages of such modernization areobvious:

»More efficient and reliable plant managementthanks to the modern operating system

»A high degree of investment protectionthrough retention of the automation andprocess level, including the field level

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Germany – flexibility and integrated safety

On the Schwarzheide site in the Lausitz, BASFAG recently opened a production facility for anentirely new crop protection chemical, just 20months after the construction work began.The automation for this facility was purchasedentirely from ABB, with the project being basedon a Melody control system for automating thebatch process. The plant contains a total of 19 operator terminals, two of which are locatedin hazardous areas. Altogether, 14 Melody con-trollers have been installed and four of thesehave been designed to be redundant.In addition to the company’s positive experienceof working with ABB in the past, the main rea-sons for choosing the Melody system included:

»The easy means of coupling 20,000 tags toBASF’s customized process information man-agement system (PIMS)

»The possibility of using the system fieldbus toconnect to the fail-safe system of HIMA

»The possibility of a redundant design»The optional Ex-i execution of the process

interface modules

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Norway – perfect integration

The gas processing facility of Statoil in the Nor-wegian town of Kårstø processes natural gasand condensates from off-shore platforms inthe North Sea. Ever since it was built in 1983,the plant has been operated using ABB sys-tems and has repeatedly been upgraded to thelatest system technologies. In a recent exten-sion, which aimed to double production capaci-ty and integrate an additional production line,the company chose to use Melody as its con-trol system.At the same time, a central control room hadto be built, which was to immediately mergeand replace the existing ones.

There were several good reasons to chooseMelody for this conversion, for instance:

»The intrinsic safety while setting up and con-verting the process plants

»The minor effect on operations as thechangeover was carried out “online”

»The high degree of investment protection asthe system is open for extensions

»The easy means of asset optimization and theresulting reduction of process costs.

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Germany – the heart of sugar production

Production at Nordzucker AG in the northernGerman town of Uelzen has recently come torevolve around Melody, with which various,previously autonomous, parts of the plant areinterconnected. In addition, this open processcontrol system has been used to interface to18 different suppliers and integrate them toform one complete system, making all processinformation available in one central location. Inthe future, too, Nordzucker will continue to relyon the open features of Melody and that iswhenever it needs to connect several silos tothe plant.

Melody was chosen here due to the specialadvantages it has particularly in the area offood industries. These include:

»The open system concept for the smoothintegration of field devices and easy connec-tion to the fieldbus

»The full redundancy for increased availability»The easy way in which production conditions

can be adapted, during operation as well asin parallel to operation

»The fact that it can also be used in validatedplants using special functions such as theaudit trail

» The comprehensive library of function blocks

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Melody goes Industrial IT: Theprocess control system at a glance

Hierarchical system structure»Operator and management level: Operate IT

Process Portal, Produce IT Batch» Control level: CMC70 Control IT Controller» Input/output units: Melody Rack I/O, Control

IT S800/S900 PROFIBUS remote I/O»Melody Composer engineering tool: planning,

engineering, commissioning, diagnostics, andmaintenance

»Further Industrial IT components for plantoptimization (Optimize IT) and for informationmanagement (Inform IT) can also be integrat-ed.

Redundant bus networkReliable communications network for all auto-mation areas, such as the operator level, con-troller, process interface, and fieldbus compo-nents.

Scalable redundancy, full system supportIntegrated redundancy concept in power sup-ply, communication, functional units, and pro-cess interface, as well as high availability withno additional configuration effort

CMC70: a powerful Control IT controller Comprehensive scope of common and cus-tomized, industry-specific process functions,redundant, integrated interfaces to MelodyRack I/O, redundant, integrated PROFIBUSinterfaces to fieldbus stations and devices, andautomatic redundancy handling.

Intelligent process interface Broad range of I/O modules with an optionallyintegrated Ex-i interface and a power supply tothe sensors. Functions with 1 ms time stamp,integrated HART interfaces, assembly of the I/Omodules optionally in the cabinet or junction boxon site, reliable bus connection using redundantfiber-optic cables.

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PROFIBUS and Control IT I/O stations (S800,S900) for Ex-i and non-Ex applicationsTwo redundant PROFIBUS DP lines for eachCMC70 controller, optionally copper and/orfiber-optic connection with the I/O stations andProfibus devices; possibility of simultaneousconnection of Profibus DP and PA devices viaDP/PA couplers, on-site assembly of Control ITI/O stations (S800, S900) for non-Ex and Ex-iapplications, including installation in zone 1hazardous areas.Melody Composer: an comprehensive engi-neering toolEfficient multi-user engineering tool for plan-ning, engineering, commissioning, diagnostics,and maintenance; parallel engineering of plan-ning and operating phases, function-chart-ori-ented user interface, seamlessly integrated fielddevice planning and configuration for PROFI-BUS and HART, field device configuration withFDT/DTM.

Operate IT Process Portal: a modern humansystem interfaceScalable operation and visualization system,with the data for all process areas being ac-cessed directly using objects and the associat-ed aspects. Uniform operating concept, inte-gration of live videos from the plant, security,and overview thanks to intelligent window man-agement.

Produce IT Batch: flexible recipe processingOptimized additional package for recipe pro-cessing, scheduling, and batch production,automatic execution of recipes, recipe manage-ment, configurable redundancy, deployment ofthe NAMUR and ISA S88 standards.

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The IndustrialIT wordmark and all above-mentioned product names in the form XXXXXXIT are registered or pending trademarks of ABB.

Automation TechnologiesDudenstrasse 44-4668167 Mannheim, GermanyPhone: +49 (0) 1805 266776Fax: +49 (0) 1805 776329 www.abb.com/processautomation E-mail: Marketing.Control-Products@de.abb.com

Do you still have questions?

If you desire further information, please do nothesitate to contact us. We will be happy toanswer any questions you may have about theMelody Industrial IT system. Just use the ad-dress below to get in touch with us.

»Success factor: built-in safetyOperate IT Process Portal: the modern andscalable operation and visualization system thatallows even complex plants to be controlledreliably.

»Success factor: enhanced qualityProduce IT Batch: the tool that allows you tocreate and manage recipes in a simple andverifiable manner. Thanks to the fact that thetool is consistently user-friendly at all levels –from the recipe to the tag – you can enjoyenhanced quality and optimized use of yourplant.

Melody – the success factors at aglance

»Success factor: high availabilityMelody: The modular process station offers awide scope of process functions for variousindustries. The redundancy concept – includingcontrollers, I/O modules, and fieldbuses –ensures high availability of the whole plant.

»Success factor: increasing efficiencyComposer: this efficient engineering tool sup-ports users throughout the entire life cycle of a plant, providing functions for planning, con-figuration, commissioning, diagnostics, and formaintenance. The field devices are configuredin a highly efficient manner using the FDT/DTMconcept.