Heritage Evolution Stepwise Advant Evolution to 800xA

Size: px

Start display at page:

Download "Heritage Evolution Stepwise Advant Evolution to 800xA"

Margaret Priscilla Daniel
5 years ago
Views:

1 Glenn Törnkvist, BU CT Heritage Evolution 2016 Heritage Evolution Stepwise Advant Evolution to 800xA Slide 1 -

2 security 800xA It s all about control...costs productivity Slide 2 -

3 It s all about Control Everyone has the same picture of what s going on in the plant Slide 3 -

4 It s all about Control Fully utilize Heritages Systems plant assets in 800xA 800xA Collaboration Table Alarm Analysis Slide 4 -

5 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 Reports Faceplates Trend Graphics Video Asset Health ERP/ CMMS Documentation Slide 5 -

Typical Heritage systems installation Advant

with PU410 S100 I/O AC450 AC 800M CI856 to S100

Base System Servers DMZ MI Servers Internet CMMS

S800 I/O Variable Speed Drive S800 I/O LV

6 Typical Heritage systems installation Advant Station Advant Station 140 Control Builder: Laptop with PU410 S100 I/O AC450 AC 800M CI856 to S100 I/O AC 800M Motor Controller WirelessHART gateway Base System Servers DMZ MI Servers Internet CMMS ERP DMS CAD Video Variable Speed Drive TU40x with S800 I/O Variable Speed Drive S800 I/O LV Switchgear S800 I/O S800 I/O WirelessHART Business Systems Slide 6 -

7 Typical Heritage systems installation Do risk increase by the age of a system? Advant Station Advant Station 140 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 AC450 ABBs suppliers have increasing difficulties maintaining test systems for older parts and sourcing components making it harder for ABB to support our older products S100 I/O Variable Speed Drive 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... S800 I/O Slide 7 -

8 Six main areas Operator Interface (HMI) Engineering Tool Communications network Controllers I/O s Drives Slide 8 -

Evolving the HMI - challenge Operator Interface (HMI) Obsolete hardware and Software: HP Unix Workstations, Monitors and keyboards PC Workstations

9 Evolving 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. Slide 9 -

10 Evolving the HMI - solution Operator Interface (HMI) Evolve HMI to: 800xA Revision Investigate and Utilize 800xA Extended Automation values in the Evolved Heritage system HMI tool-based graphics Evolution from Unix or VB6 to PG2 Service provided by ABB Use Automation Sentinel Maintain and Evolve Changes: 800xA requires PU410 for communication with the controllers and engineering tool. All RTA modules of PU515 and PU516 series must be replaced. Slide 10 -

Evolving the Engineering Tool - solution Engineering Tool PU410 communication box for MB300 and Serial Interface Flash card programmer: OmniDrive USB2 LF(/SD) CardWare 7.

11 Evolving 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 2015 Control Builder A 1.4 for Windows 8.1 and Windows 2012 Server and Windows 7 Slide 11 -

System 800xA the climb Alarm Response, Shelving, Analysis, Grouping, Alarm Help Tabbed Navigation w/ Alarm Status Extended Operator Workplace Mobility guide Smart client w/ PG2 Graphic Support Point

12 System 800xA the climb 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 5 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 Large screen / Multi-screen Digital Security Improvements Virtualization offering for 800xA MS WPF Graphics (PG2) Snap-shot report Multi-system Integration Alarm and Event Improvements Remote Clients via MS Terminal Services 3 First version release w/ complete system concept Single environment from independent solutions Redundancy on all levels Slide 12 -

Human-Machine Interface Evolution Services by ABB Worldwide delivering to customers since 2005 Key offerings: Standardized conversion Tool based one-to one conversion of 800xA Visual Basic graphics

13 Human-Machine Interface Evolution Services by ABB 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 platform capabilities: 3D objects, animations, optimizations Remote support Complete ABB DCS System Evolution project management Slide 14 -

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

14 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. Slide 15 -

After some more years the communication fails.

15 Evolving the Communications System - challenge MasterBus 300 Communications network Yellow cable and transceivers ages - increase re-sendings that slows down the communication speed. After some more years the communication fails MasterBus 300 Thick Ethernet Trancievers Spares for transceivers and Ethernet HUBs not available MasterBus 300 Ethernet HUBs Slide 19 -

16 Evolving the Communications System - solution MasterBus 300 Communications network 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 MasterBus 300 ABB Switches Slide 20 -

discontinuity in the rack backplane Dirtiness The CPU has passed

17 Evolving 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 1984 MP AC AC450 Slide 21 -

18 Evolving the controller - solution Controllers Controller replacement MP200, AC410, AC450 to AC 800M Stepvise replacement of controller due 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 AC 800M Slide 22 -

Achieving seamless control Several Ethernet based protocol that provides intelligent data from the field to support a higher plant

different communication with one single tool Flexible to all device manufacturers and in brownfield installations Support of Heritage

Mix up to 12 communication interfaces to each AC 800M Support of User defined protocol (serial and Ethernet based) CI873 Ethernet /IP

19 Achieving 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) CI873 Ethernet /IP DeviceNet CI871 ProfiNet CI868 Electrical CI867 Integration Modbus IEC TCP CI860 Foundation Fieldbus HSE CI854A Profibus DP CI853 Serial Modbus Serial DeviceNet via Gateway Slide 23 - Foundation Profibus PA Fieldbus H1 via Linking via Linking Device Device

20 Evolution of Advant Master to AC 800M Key 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 Slide 24 -

Engineering of AC 800M in Control Builder M Control Diagram

Parallel engineering supported Open interface (XML) Modern

dialog with recent and favorite lists Undo / Redo several steps

21 Engineering of AC 800M in Control Builder M Control Diagram Editor Easy 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 Slide 25 -

22 Engineering of AC 800M in Control Builder M Function Designer for top down design Slide 26 -

23 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 Slide 27 -

24 PAPI Sweden controller application software evolution Reference list September 2015 Slide 28 -

25 Advant Master application software evolution to 800xA MP200, 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 Slide 29 -

26 Evolving 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 1978 S100 Slide 30 -

Evolving 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

27 Evolving 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 S100 version A 2016 (planned release) S100 version A, G3 coated Slide 31 -

Rack I/O Evolution AC800M Interface to S100 I/O CI856, S100 I/O connector The communication board CI856 together with the control software gives support for migration of the installed base of S100

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.

28 Rack I/O Evolution AC800M Interface to S100 I/O CI856, 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 times DSAI 133 / 133 Analog input board, 32 ch. DSDI 110 /110A /110AV1 Digital input board, 32 ch. 24V DSDI 120 /120A /120AV1 Digital input board, 32 ch. 48V DSDO 110 Digital output board, 32 ch. DSDO 115 Digital output board, 32 ch. DSDO 115A Digital output board, 32 ch., OSP control DSDO 130 Digital output board, 16 relay ch., VAC/VDC DSDO 131 Digital output board,, 16 relay ch., VAC/VDC DSAO 110 Analog output board, 4 ch. DSAO 120 Analog output board, 8 ch. DSAO 120A Analog output board, 4 ch., OSP control DSAO 130 Analog output board, 16 ch. DSAO 130A Analog output board, 16 ch., OSP control DSAX 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. Slide 33 -

29 Evolving 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 Slide 34 -

30 Evolving 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 Slide 35 -

31 Stepwise Evolution from AC450 to AC 800M Reuse of Advant OSC Cabinet Redundant AC450 with S100 I/O System Advant 800xA OCS System Advant 800xA OCS 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 Slide 36 -

32 Key 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 Slide 37 -

Evolution of SattLine DCS and of SattCon PLC

EXTERNAL Satt Evolution Evolution of SattLine DCS and of SattCon PLC January, 2019 Operating and maintaining the control system What are the challenges today? Which ones are relevant to our customer? Plant