ABB 800xA

 Project uses ABB 800xA version 5.0 with SP2.

 800xA V5.0 is developed in Visual Basic platform.
 Promoting collaboration through integrated plant
systems and applications
 Improving operator effectiveness through
integrated information
 Generating cost effective solutions through
integrated engineering
 Achieving seamless control through integrated,
unified fieldbus networks
 Providing flexible evolution paths through
seamlessly integrated controller platforms
Process Graphics
Process graphic screens are mainly segregated
into 3 different levels of hierarchy

 Level 1 - The complete plant overview.

 Level 2 - Sectional overview (constitutes
overview graphics from section 2000 to section
2900 ).
 Level 3 - Detailed screens of each area.
Additional Graphic screens
The main menu provides access to all sections of
the process graphic screens and its related sub-
screens. The sub-screens includes.

 FGS/ESD Screens.
 MOS screens
 Pump runtime hour display screens.
 Flow totalizer screens.
 Cabinet Status and system architecture

A help menu is provided on each screen for quick reference and guidance.
Screens are facilitated with aspect link buttons to navigate from one screen to next.
Level 1 screen
Level 2 Screen
Level 3 Screen
Sample sub-screen for cabinet
status display
Graphic Elements

 Constitutes the basic building blocks of process

graphics.
 Standardized symbols for process instruments
/equipments.
 Unique representation philosophy(dynamics
/animation).
 Standardized color selection as per safety
norms.
Types of graphic elements
 DCS Transmitter – Color of real time value
changes as per High / Low alrams

 ESD Transmitter – Color of real time value and

HH/LL indication changes on alarm condition.
Digital Indicators

 Simple Indicators

 Alarm indicator with faceplate access

 MOS indicators
FGS graphic elements
 Flame Detectors
Normal Alarm Stage -blinking

 Gas Detectors
Normal Alarm Stage – blinking

 Manual Call Point

Normal Alarm Stage – blinking

 Deluge Valves
Control valves

 The control valve has no animation

 Displayed by corresponding line colour.
 Valve opening percentage is shown under the
valve picture with Tag name and unit.
Choke Valves

 The Choke valve has no animation

 Displayed by corresponding line colour.
 Valve opening percentage and feedback
transmitter value are shown with Tag name and
unit.
On/Off valve
Animation philosophy
Valve condition Open Limit Close Limit Switch Command Valve Icon
Switch signal
Valve open 1 0 1 Filled Line Colour
Valve commanded closed 0 0 0 Unfilled Line Colour
and in travel blinking
Valve commanded closed 0 0 0 unfilled line colour
– Failed to close blinking
Valve closed 0 1 0 Unfilled Line Colour
Valve commanded open 0 0 1 Filled Line Colour
and in travel blinking
Valve commanded open 0 0 1 Red filled
– Failed to open

Representation
On/Off valve animations
Pumps
Animation Philosophy
Motor Status Status2 Status3 Status4 Command Command Screen
Condition signal signal signal signal signal signal2
RUN STOP FAULT AVAILABLE START STOP
Stopped 0 1 0 1 0 1 Unfilled line
colour
Running 1 0 0 1 1 0 Filled line
colour
Failed to 0 1 0 1 1 0 Blinking
start and unfilled
line
Failed to 1 0 0 1 0 1 Blinking
stop and filled
line colour
Fault X X 1 1 X X Red

Unavailable X X X 0 X X Red with

cross mark
on the icon

Representation
Pump animations
Fin Fan Cooler
Animation Philosophy
Motor Status Status2 Status3 Status4 Command Command Screen
Condition signal signal signal signal signal signal2 Display
RUN STOP FAULT AVAILABLE START STOP

Stopped 0 1 0 1 0 1 Grey
Running 1 0 0 1 1 0 Green
Failed to 0 1 0 1 1 0 Grey
start Blinking

Failed to 1 0 0 1 0 1 Green
stop Blinking

Fault X X 1 1 X X Red
Unavailable X X X 0 X X Red with
cross mark
on the icon

Representation
Fin fan cooler animation
Level Indicators
 Indicates the level of the corresponding vessel.
 Indication turns yellow on high / low alarms.
 Indication turns yellow on high high / low low alarms.

ESD-DCS switch
 Represents which transmitter is used for control of output valve.
 Buttons blinks in case of deviation in values between DCS/ESD
transmitters.
Process Lines
 The thickness and color of process lines varies as per content of
the gas/fluid through the line.
 Color and thickness for a particular gas/fluid content will be
unique.
Process lines and colors used are shown below.
Interlock indications
 These are alerts for any ESD trip in particular
equipment/instrument.
 Remains invisible in normal conditions.
 Blinks in case of alarms.
 Faceplate displaying the cause of trip could be opened
by clicking over the GE.

1.ESD interlock blinking 2. Sample faceplate of an interlock

Faceplates
 Designed mainly for operator use, to monitor and affect
control of a process.
 All graphic elements which needs detailed monitoring and
control, are provided with faceplates.
 Each object can have up to three different sized faceplates,
depending on the needs of the object and the user(Reduced,
Standard & Extended).
Each faceplates are divided into 5 sections
 Header Area
 Status Indication
 Faceplate Element
 Control Button area
 Faceplate size control area.
Faceplate for input transmitters
Faceplate for output transmitter
Signal Processing
PID – Proportional Integral Derivative Control

 Provides real time displays of input Pv.

 Provision for entering setpoint (by supervisor/maint engg)
 Provision for tuning parameters.
 Provision to select direct/reverse action.
 Trend display of Pv, Sp and Out.
 Auto/ Manual selection switch.
 Provision to select Ext. Sp for cascade PIDs.

.
Sample PID controller faceplate
PID-cascade block diagram
Manual Loader
 Used where inputs are to be controlled by the operator.
 The operator are able to force the output by enabling the manual
mode.
 In auto mode, the manual loader transfers the same input value to
the output.

The block diagram representation of a manual loader is shown below.

Manual Loader faceplate
Split Range Control
 The input to the split range controller is divided into
two ranges which can set independently, and may
overlap each other.
 Output ranges could be set in maintenance engineer
mode.
Block diagram representation of Spit Range system used in
the project is shown below.

Split range control does not have a faceplate by default, hence cannot be controlled
by an operator.
Ratio Control
 The Ratio Controller is used to multiply the connected input with the
ratio percentage provided by the operator and provides the final output.
 The ratio could be entered manually by supervisor/ maint engg through
the faceplate.

Block diagram of a ratio control is shown below.

Ratio controller faceplate
Min Max Control
Min Control
 Selects the minimum value of the two input values.
 The selected line is highlighted in the process graphics.

Max Control
 Selects the maximum value of the two input values.
 The selected line is highlighted in the process graphics.
Flow Compensator
 Provides the compensated flow value of the particular process line.
 The flow computer(software) calculates the the compensated value
using the temp, pressure and flow inputs of the process line.
 The compensated values are integrated to display the total flow of day
or particular time period till it is reset.

Diagrammatic representation of flow compensator.

Motoruni
 Used for pumps and fin fan coolers.
 Contains provision for auto/man mode selection.
 Provision for start/stop and output status.
 Provision to monitor the feedback signals.
 Provision to monitor ESD trip, motor fault and unavailable signals.
Motoruni faceplate
Valve faceplate
 Used for on/off valves.
 Provision to start/stop in some cases.
 Provision to monitor the feedback signals.
 Provision to monitor ESD trip and fault signal status of the valve.
 Provision to monitor valve output status
 Alarms

 The project provides two different types of alarm lists.

Process Alarm list
Process alarm lists can either include all process alarms or alarms for a specific part of
the process down to a single process object.
System Alarm list
System Alarms are alarms generated from the 800xA System, such as network
problems, file system errors or server errors.
Both the alarms lists could be accessed from the application tool bar in the operator
workplace.
 Each alarms are segregated according to its priority.
 Alarms can have different priorities that are indicated by different colors.
 An alarm list only includes the alarms that an operator needs to pay attention
to, such as unacknowledged or still active alarms
 All alarms will be added to event list.
Sample process alarm screen
Alarm list
Alarm list configured is easy to understand and user friendly
Alarm list displays
 Acknowledge state
 State
 Priority level (1- 4)
 Time of occurrence
 Object name
 Object description
 Condition
 Message
Unacknowledged and active alarms gets highlighted and blinking in the
alarm list.
It is possible to acknowledge alarms from the alarm list/corresponding
faceplates.
Acknowledged and inactive(returned to normal) alarms get deleted
from the alarm list automatically and gets stored in event list.
Priority levels
Each alarm is configured with an OPC-severity code between 1000 and 1.Value
1000 is normally mapped as most critical but this is configurable as long as the
mapping is consistent throughout the system.

Prioritization of alarms can also be done depending on the level of criticality.

 Red – priority level 1 (All ESD/FGS alarms )
 Orange – priority level 2( DCS alarms - Fault/Deviation/ Channel error etc.)
 Yellow – priority level 3 (DCS alarms -High & Low alarms )
Alarm animations are considered according to the following
 New Alarm - Flashing
 Operator acknowledged Alarm – Steady
 Alarm Inactive – Steady Grey
Critical alarms , based on its priority are made audible for operator alert.
Event list
 The Event List display lists all events matching the configured event
filter.
 The event list functionality is the same as for the alarm list, except
for the acknowledge feature.
 All Alarms have events but all events does not have alarms.
 Event list includes operator actions, change of parameters like set
point, system / process related warning message.
 Events are classified according to its priority levels and shown in
different colors.
Sequence of Events (SOE)
 Displayed in the same manner as that of event list but in different
event list page.
 These are events which are detected at the initial stage from the
point of occurrence (directly from IO card) which caused a chain
trip action.
Sample Event list
Remote HMI
 The project make use of touch-panel HMI for sections
SGS JIHAR AND SGS AL MAHR
 Makes possible for independent remote control of the
specified areas.
 SGS- Jihar and SGS- Al Mahr areas could be controlled
from both DCS and PP865 system.
 Control action from one system gets updated in the
other one automatically.
Specification
CPU
 • A 300-400 MHz Intel Xscale CPU
 • Windows CE 4.2 Operating System
Memory
 • 32 Mbyte Intel Strata Flash Memory
 • 12Mbyte Flash for application ( expandable via Compact flash slot)
 • 64 Mbyte RAM
High quality displays
 • 64 000 Colors TFT
 • Wide viewing angles
 • Excellent screen resolution
Dimmable LCD-backlight
 • For offshore and infrastructure
 • Controlled by PLC or manually
RS232 port
 • Dsub, 9-pin
Combined RS422/485 port
 • Dsub, 25-pin
Built in Ethernet port
 • Twisted pair
 • Fast Ethernet 10/100 Mbit
PP865 project specified features
 Uses same DCS graphics philosophy for display and animations.
 Navigation is made possible by use of aspect links to move from one
screen to another. Manually pressing over the aspect links in the
screen makes it possible navigate to specified locations.
 The main menu provides link to all process screens.
 Clicking over the pump/valve/PID controller/interlocks will take to
respective faceplate screen.
 Features like auto /man switching, change of setpoint, valve open/close,
valve reset etc could be performed through the HMI.
 The real time values of field instruments are obtained directly from
respective DCS controller and are displayed in level indicators/value
display fields.
 Control signals from PP865 will be transferred directly to DCS
controller.
 Generates its own alarm list (with similar features as that of DCS
system).
Main menu HMI screen
Sample process graphics screen
Alarm Screen
PID controller sub-screen