System 800xA Overview

High integrity automation solutions for continuous productivity improvements

Systems Marketing

Extended Automation System 800xA

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Agenda

Introduction to System 800xA System Architecture

Operations
Engineering Safety

Device Management
Asset Optimization Information Management

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Market Forces

Reduced Capital Spending

Due to global competition, process industries forced to re-evaluate business models and implement continuous improvement initiatives

Increase of Different Systems

Data Access Problems

Threats to productivity

Fewer Resourcesmore data!

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Traditional Automation
Programmable Logic Control

Motor Control Centers

Asset Optimization

Information Management

S88 Production Management

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Advanced Control Instrumentation & Drives Safety

xA = Extended Automation
Redefining the Automation System Standard

A single operations, engineering and System 800xA information management environment for an Extended Automation scope

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and further enhanced with certified products

Industrial IT solutions build upon the 800xA extended automation system with integrated devices and 3rd party software applications to deliver value for our customers.
Industrial

ABB and 3rd party

IT Technology Partnership Program

System 800xA

Integrated ABB

& 3rd party products complete the Industrial IT portfolio to work with System 800xA

Certified

Certified Products

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System 800xA What the Media Reported

The Search for Automation's Holy Grail - ABB's New Extended Automation Suite Leads the Quest
Control Magazine, January 2004

Automation system eases asset management, predictive maintenance. ABB Inc.'s Industrial IT System 800xA extends the scope of traditional control systems
Plant Services, February 2004

System 800xA Extends Functionality Of Traditional Automation Systems

Instrumentation and Automation News (IAN), March 2004

New system reaches beyond automation

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Control Solutions, February 2004

System 800xA Market Acceptance

Widely embraced by both new customers and ABB installed base Used to extend automation functionality in a wide variety of applications

Oil & Gas Pulp and Paper Biotech/Pharmaceutical Utility Chemicals/Fine Chemicals Metals Mining

More than 2,700 systems sold worldwide since release in January 2004!

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System 800xA Quiz Question 1. What does the xA in System 800xA stand for ? a) Extended Automation b) ExActly what you make of it c) ExtrA Special

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Integrated system environment

System Architecture

Extended Automation System 800xA

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Information that Follows the Asset

Control

The System 800xA platform lets you monitor, control, optimize, and maintain from one powerful interface.
Aspect Object Technology

Faceplates

Zoom in to any level for fast Trend answers, action, or asset Contextual navigation based on the users jobGraphics management

function and the task at hand allow real-time Logical, object-based access decision making and action to every component
Attach information just once for instantiation across multiple systems

Video

Asset Health Reports CMMS / Calibration Documentation

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Follow your thought!

System Architecture

One common platform for all software products

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Extending the Scope

Predefined process objects

Enter configuration only once Faceplates, Graphic Symbols Alarm management Trend, History Documentation Device Management Asset Monitor, CMMS Etc.

User defined objects

Pre-defined Libraries Composite Objects

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Library types

One change automatically affects all instances

System Architecture

Efficient Engineering

Object oriented Inheritance

Control Network

Location

Plant Areas

Organization

Personalization Filtering
System Management Regulatory Requirements Data shared between applications

One Stop Shopping!

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System 800xA Architecture

Aspect Server(s) Connectivity Server(s) Application Server(s) Local and Remote Personalized Workplaces

Extended functionality doesnt mean large. The 800xA system provides you the flexibility to start small by implementing the functions you require today, and the ability to expand as needs evolve.

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Controllers and I/O

Compact Products 800 Architecture

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System 800xA Architecture - Evolution

Enhancing your installed DCS
Remote Clients

System 800xA Workplaces

Operator Engineering Maintenance

System 800xA Supported Controllers

Harmony Advant AC800M DCU

Advant Master Advant MOD 300

SafeGuard Sattline DCI Harmony AC870P PlantGuard

Process AC800M Automation and Safety Controllers

I/O : S800,S900,

Harmony Freelance INFI 90 Melody

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TDC3000

Comprehensive Controller Solutions

State-of-the-art controller family suited for all plant needs

Small Hybrid applications Large, integrated automation and safety applications

800xA Control & I/O includes:

AC 800M Controllers AC 800M High Integrity Controller S800 I/O S800 High Integrity I/O

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Scalable Performance
Choice of speed, memory and availability
Redundant PM864 PM864 Redundant PM861 PM861 PM860 PM856 PM851 16MB 48 MHz 8MB 48 MHz 32MB 96 MHz

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8MB 24 MHz

8MB 24 MHz

AC 800M Architecture
Optional up to 12 Communication modules

CPU

S800 I/O

PROFIBUS DP/V1 FOUNDATION Fieldbus RS232C MasterBus 300 INSUM Switchgear S100 I/O Drivebus

2 RS-232 channels Redundant Ethernet

Totally can up to 96 S800 I/O modules be connected as direct I/O to AC800M

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Up to 12 I/O modules can directly be connected to the CPU via the electrical Modulebus

Up to 84 I/O modules can be connected via I/O clusters via the optical Modulebus

S800 I/O Modular three part design

Fieldbus Communication Interface (FCI)

ModuleBus PROFIBUS, also redundant

I/O module

Full range of signal types including AI, AO, DI, DO, Temp, Pulse, Freq, HART, IS interface, SOE
High Integrity Hot-swap

Redundancy

Termination unit

2-wire Compact design 3-wire Extended design, also with fuses Mechanical key and locking/activation tab

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Full redundancy No single point of failure

Redundant PROFIBUS master interface Redundant CPUs with optionally redundant CEX buses (max 12 communication modules totally ; SM810 take one address)

No S800 modules on electrical Module bus !!

Remote S800 I/O via PROFIBUS DP/V1 (optionally line redundant)

Control Network (Ethernet TCP/IP, 10Mbps)

Max 12 S800 modules per I/O cluster

Max 24 S800 modules per remote I/O station

Optionally redundant S800 modules (max 6 pairs per I/O cluster)

Max 12 S800 modules per I/O cluster Optionally max 6 pairs of redundant S800 modules on base cluster. ABB - Page 24

Max 7 S800 I/O clusters Max 99 remote I/O stations Max 12 S800 modules per I/O cluster

System 800xA Quiz Question 2. Which answer below would NOT be an aspect of a control tag in System 800xA?
a) Faceplate
b) Trend c) Alarm List d) Alarm Instructions e) Historical log configuration

f) Loop Performance Asset Monitor

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g) Roys coffee mug

System 800xA Core Functional Areas

Operations Engineering Safety Device Management Asset Optimization Information Management

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Reducing time to decision and action

Operations

Extended Automation System 800xA

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System 800xA Operations

Reducing Time to Decision and Action

Quick, flexible and secure access to information Extensive functionality for handling normal and abnormal conditions Customized user environment to meet individual needs Re-defining the meaning of operator workplace
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Industrys most complete user interface

System 800xA Operations

Reducing Time to Decision and Action

Aspect Object Technology

Intuitive access to relevant, filtered information

Right information to the right person at the right time Filtering Capabilities Alarm Hiding

Quad Display

Personalized Workplaces

Alarm Management

Extended Operator Workplace

SMS Messaging

Paging, Email, Text Messaging

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Quick Response to Plant Conditions

Consistent call-up using the right mouse button

References to all process graphics and displays where object is represented Display links and Short cuts Favorites and History Lists Back and forward buttons Programmable hot keys

Intuitive Navigation

Access to distributed information

Intuitive and flexible navigation for fast information access

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System 800xA applications ABB products and equipment Third party applications

Presenting Relevant Information

Different workplace layout adjusted to individual preference and needs

Management Workplace Operator Workplace Maintenance Workplace

Operator Advanced Operator Maintenance Engineer Plant Manager

Menu and toolbar content focused towards individual user

Filtered context menu based on user function

Personalized workplaces for focused information access

User profile based upon security log-in

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Log-over Authentication

Alarm Philosophy - Personalized Workplaces

Operator Operator Operator Operator A D C B

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Engineering for maximum performance

Engineering

Extended Automation System 800xA

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System 800xA Engineering

A fully integrated engineering environment for the development and re-use of intellectual assets throughout the entire plant lifecycle Standards can be defined, deployed and tested at any level Automatic change propagation through object inheritance Reduces testing and validation Automated incorporation of control strategy standards and I/O data Companies who develop and utilize standard control solutions have realized a 50% cost reduction in engineering

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Enhanced IEC 61131-3

All languages can be used simultaneously in the same controller Control Modules

Instruction List

Can consist of a mix of IEC 61131-3 languages Hide control logic details inside Control Modules Store Control Modules as proven solution system library Reduced engineering effort and improved quality through reuse

Function Block Sequential Function Charts

Structured Text

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Ladder Logic
Control Modules

Control Module Diagram

System 800xA Engineering

Engineering for Maximum Performance

Single Source for accurate, consistent automation system data Value added engineering instead of programming Total Asset Lifecycle engineering Fully integrated engineering environment for development and re-use

Intuitive Graphical Function Design

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Inheritance is a good thing

Re-use Instead of Re-inventing

Object Type Object Type

MotorControl

Motor 1

Motor 2

Object Object Instances Instances

Motor 3

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Motor 4

Inheritance is a great thing!

Inheritance ... change an object type once and the change is reflected on each object instance

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System 800xA Engineering

Engineering for Maximum Performance Modify

Object Oriented Engineering Function Designer and Bulk Data Manager Application Libraries Process Engineering Tool Integration

Load Evaluate Go

Load

SV5+

Evaluate

Intergraph SPI integration

Abort/Go

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Multi-User and Distributed Engineering Multi-System Integration On-Line Change Evaluation

Accept/Revert finished

Reducing risk through high integrity automation

Safety

Extended Automation System 800xA

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Closer integration of safety and control

BPCS and SIS delivered in a single environment eliminates interfacing, cost and complexity, and widens the function scope

When executed within the same controller, 800xA safety and process applications can freely exchange signals and data without need for external, complex interfaces and mirroring of data

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Embedded safety and process control

Simplified operation and maintenance

Embedded environment reduces duality and associated lifecycle costs of maintaining separate systems (i.e. less spare parts, common training, etc.)

Same engineering tools Same human systems interface Same Alarm Management and SOE Same historian Same audit trail Same asset and device management Same or shared instrumentation Separate control applications for BPCS and SIS

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Embedded safety and process control

System 800xA Safety

Reducing Risk through High Integrity Automation

To combine or not combinethat is the question

Workplace Workplace

Workplace

Workplace

Control Network

Process Automation

Communication link

Process Automation and Safety

Safety

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Separate Systems

System 800xA Safety

Reducing Risk through High Integrity Automation

To combine or not combinethat is the question

Workplace Workplace Workplace

Control Network

Process Automation

Safety

Process Automation Safety

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Same controller, system, separate controllers Same separate applications

System 800xA Safety

Reducing Risk through High Integrity Automation

Flexible and scalable design for combined or separate operation System 800xA AC800M High integrity control and I/O includes: AC800M HI S800 I/O
Access Management

SIL Application Environment

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SIS scalability results in higher return on assets by providing the flexibility to choose the specific safety functions required to meet actual plant needs

System 800xA Safety

Safety Module SM810

Processor Module PM865

S880 I/O modules

C
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System Alarm Force Present

Access Enable

Reset all forces

AC800M High Integrity Access Management

Provides functions for protection of SIL classified applications in AC800M HI Controllers

SIL Access Control and Authorization Confirmed Online Write / Confirmed Operation Force Control /Override Control /Bypass Management
Embedded firewalls and confirmation procedures protect the SIL application from inadvertent / accidental control actions

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Safety SW - Application Libraries

System BasicLib MMSCommLib AlarmEventLib ProcessObjLib SupervisionLib FireGasLib SignalLib

2
SIL2 Mark

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SIL compliant application environment

Engineering system will automatically limit user configuration choices

2
SIL2 Mark

IEC61131-3 languages used limited to Function Block, Structured Text, and SFC for SIL applications Prevent download if SIL requirements are not met Safety measures implemented for downloading process and runtime environment Embedded firewall mechanisms to prevent outside interference

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CRC protection on different levels Double code generation with comparison Compiler with revalidation

System 800xA Quiz Question 3. For System 800xAs High Integrity controller to be used, you MUST run both control and safety in the same controller.
a) true

b) FALSE (pick this one)

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Optimizing plant asset availability and performance

Device Management & Asset Optimization

Extended Automation System 800xA

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System 800xA Device Management

Freedom of Choice

Relevant device status, diagnostic, and process information available wherever needed Full range of certified devices pave the way for seamless implementation

Over 500 devices available

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Freedom of choice to cover a broad range of applications Preconfigured device objects for accessing device data, asset information, and documentation

Device Library Objects

Real Object Each device type object includes aspects for
Product Documentation

Configuration Commissioning Operation Maintenance Management Parameterization Asset Monitoring Diagnosis

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Object Type, delivered with the Device Type Library

System 800xA Asset Optimization

Optimizing Plant Asset Availability and Performance

Scheduled monitoring of asset health status and event driven condition reporting Provide root cause analysis data and recommended action information Reduces downtime and mean time to repair Reporting and analysis visualization tools
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Maintenance Workplace

Asset Tree Viewer

Asset Reports

Reliability Centered Maintenance Enabler

System 800xA Asset Optimization

Pre-configured asset monitors exist for wide range of assets:

Not just for smart instruments anymore Tool Kit Available

User-defined Asset Monitors

Integrated CMMS

Maximo, SAP, IFS

Calibration Management

Integrated Device Management

Automatic Monitoring of Maintenance Conditions and Automatic Alarms

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Not just for smart instruments anymore

Standard Asset Monitors

Control Networks

Boolean check, High/Low Limit, Runtime, Counter, Flow Delta, X-Y Deviation Control Loop Performance

System Status Advanced Harmony Control System

Production Performance

Plant Equipment

Overall Equipment Efficiency

Real Time Production Intelligence

Heat Exchangers Motors and Drives Vibration Monitoring

PC Networking and Monitoring

Field Devices

Smart Devices Calibration Management Systems

Computer health, services, switches, printers

800xA node types

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Integrating information for improved visibility

Information Management

Extended Automation System 800xA

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System 800xA Information Management

Integrating Information for Improved Visibility

Provides history services for System 800xA Integrates all plant data for comprehensive views and reports Consolidation architectures
Secure historic data storage and access

Desktop Trend

Production Data Analysis

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Intuitive presentation for informed decision making Integrated administration and configuration
Ticker

Tag Browser

Excel Add-ins

Integrated Administration and Configuration

Information Management functions are tightly integrated with the system

Provides a single unified configuration database for the complete system Simplifies system administration and change management

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Simplifies and reduces initial engineering and change management

Reduced set-up and life cycle costs

IIT Technology Partnership Program

Extended Automation System 800xA

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Customer Value Message

Industrial IT is ABBs commitment to open interconnectivity of Automation and Power solutions and services, leveraging the ABB portfolio, 3rd party products and the relevant standards. Industrial IT enables ABB to provide:

Reduced Total Cost of Ownership Increased Production Output Improved Safety

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Industrial IT Enabled Products

Industrial IT solutions leverage best-in-class products from ABB and partners to deliver value in every solution area.
Infrastructure components
Software
800xA

Core Functional Areas Calibration / DMS All devices in the device PLC Connect integration library ECS Production Planning >150 HART types Connector Collaborative Production Mgmt >140 FF types ECS Toolkit >240 Profibus types Partner / 3rd Party ABB and other vendors Intergraph SPI Fisher Maximo Integration Hardware Rosemount SAP/PM Integration Connect Samson Plantguard IFS CMMS Integration Westlock ABB INSUM Matrikon ProcessGuard Positioner Valve Nilhe Video Flowserve Metso

Intelligent Devices

Hirschmann switches Cisco switches MOXA switches OnTime switches Phoenix switches Dell PC / Server HP PC / Server IBM PC / Server IBM Blade Server

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Siemens TDC3000 Connect

System 800xA for PlantGuard

Industrial IT is ABBs commitment to open interconnectivity of Automation and Power solutions and services, leveraging the ABB portfolio, 3rd party products and the relevant standards.

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Integrates Plantguard with System 800xA Automatically uploads Plantguard application into Control Structure with Tags and Descriptions Provides Object Displays for all I/O plus faceplates for intermediates Provides Plantguard alarm, events, and system status information Enables access to the Plantguard IsaGraph tools

AC 800M with MasterBus 300 connection

Plantguard 2oo3TMR SIL3

Modulebus

S800 I/O

Matrikon AlarmInsight for System 800xA

AlarmInsight with System 800xA provides a complete alarm management solution by providing certified, pre-tested, integrated system components

Steamline workflows

Direct, contextual access to ProcessGuard Alarm Analysis reports

Direct access to Operator Assistance report giving cause, effect, and recommended action Easy to implement, fill in the blank configuration Combined desktop tools with 800xAs Desktop Trends and ProcessGuards Event Viewer

Promotes consistency and decision support

Reduced engineering and maintenance

Root cause analysis

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System 800xA Quiz Question 4. Which answer below is NOT one of Industrial IT Technology Partnership Programs value propositions

a) Reduced Cost of Ownership

b) Increased Production Output

c) Improved Safety
d) To create more work for ABB and our most valued customers.
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Summary

Extended Automation System 800xA

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System 800xA Value Propositions

Squeezing more productivity out of existing assets

Reducing Time to Decision and Action Engineering for Maximum Performance Reducing Risk through High Integrity Automation Optimizing Plant Asset Availability and Performance Integrating Information for Improved Visibility Investment Enhancement through Evolution

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 ABB - Page 73