© ABB Group February 27, 2012 | Slide 1
ABB System 800xAAn Integration PlatformAutomation – Safety – Electrical – Telecommunications – Asset Management – Enterprise Level Applications
Bob DrabbantAutomation Consultant/Business Development Manager
© ABB Group February 27, 2012 | Slide 23BSE068147 en
Industry Challenges
Equipment Allignedget Systems to work togetherGet People working towards the same goalsChallenges
Industry Challanges
© ABB Group February 27, 2012 | Slide 3
People
EquipmentSystems
Seamless Collaboration is required between People, Systems and Equipment
© ABB Group 3BSE068027 enFebruary 27, 2012 | Slide 3
© ABB Group February 27, 2012 | Slide 43BSE068147 en
The Challenge
"We have an immense amount to do in graphics, in video, and in bringing a unified object approach to browsing and storing data. It´s a deep problem in computer science. A deep, deep problem. We have too many stores of data today. We have file systems, message systems, directory systems, database systems and all sorts of different software that optimizes all those things. That is not going to cut it…
...Users are going to need one integrated thing that hides all those differences."
-- Bill Gates 1997 (Giants, ISBN 0-07-032934-6)
Info Explosion
© ABB Group February 27, 2012 | Slide 53BSE068147 en© ABB / PA / Control SystemsFebruary 27, 2012 | Slide 5
Promoting CollaborationOne common automation platform – System 800xA
Data that comes from various sources can be accessed by multiple applications without
separate interfaces!
Benefits Include: Open Seat Licensing Efficient Engineering Organization of Information Shared Data
ABB_NonABB
DCS
© ABB Group February 27, 2012 | Slide 63BSE068147 en
System 800xA offering
Options
To facilitate collaboration
Core system
Basic system-wide functionality
Hardware
Controllers, PC, Network…
A unique platform for collaboration
Core SystemOperations
Control and I/OEngineering
Device Management
Hardware
Production ManagementInformation Management
Asset Optimization
SafetyEnterprise Connectivity
Applications
System 800xA
Process & Power Automation
© ABB Group 3BSE068027 enFebruary 27, 2012 | Slide 6
© ABB Group February 27, 2012 | Slide 73BSE068147 en
800xAAspect Integrator Platform
MCC’s – PMS – HV/LV/MV –IEC61850
Asset Management / CMMS
FIELDBUS
Process / Safety Controllers
Remote I/O
CONVENTIONAL
Local I/O
SAFETY
Remote I/O
Control Layer
Graphic Displays
HMI Displays
Telecoms
3rd Party PLC’s
© ABB Group February 27, 2012 | Slide 83BSE068147 en
Large Screen Displays
Client/Server Network
Control Network
Safety NetworkRedundant Server Center
Operator Workstations Engineering Workstations
Modbus RTU/TCP
MCC’s / PMS
IntegratedHistorian
HV/MV/LV SWGR
Networks
• Ethernet• TCP/IP• 1 Gbps• Managed Networks• VLAN Technology• Connectivity to existing LAN• Remote Access (via firewall)
FIELDBUS
Process Controllers
Remote I/O
CONVENTIONAL
Local I/O
SAFETY
Printers
Management Information Systems
Firewall
Remote I/O
CONVENTIONAL
PLC Connect
AnalyticsDUAL I/O
Safety Controllers
Telecommunications
Portable Client PC’s (Zone 2)
Radio Links
Addressable
F&G
HI Safety Controllers
800xA System Architecture
800xA Offering Overview
800xA Basic Functionality
800xA Operator Effectiveness
800xA Integrated Process and Power Automation
800xA Integrated Safety
800xA Integrated Historian
800xA Integrated Enterprise Asset Management
800xA Integrated Simulation Environment
Summary – 800xA ABB’s collaboration and control system
© ABB Group 3BSE068027 enFebruary 27, 2012 | Slide 10
800xA - A single user environment throughout the plant
© ABB Group February 27, 2012 | Slide 11
Everyone gets the same view of plant activities
Operations
Engineering
Maintenance
A plant centric view of all information independent of system
One common way to handle all functions
One common user language
One way of working
© ABB Group 3BSE068027 enFebruary 27, 2012 | Slide 11
Standard Operating Procedures
Internet/Intranet
Operator notes
What if...Operators always had seamless access to operational data regardless of source
Process Automation DataIncluding 3rd Party Data
Live Video
Faceplate
800xA IndustrialIT – Information Flow
The System 800xA platform lets you monitor, control, optimize, and maintain from one powerful interface.
Zoom in to any level for fast answers, action, or asset management
Logical, object-based access to every component
Attach information just once for instantiation across multiple systems
Aspect Object Technology
Control
Faceplates
Trend
Graphics
Video
Asset Health
Reports
DocumentationCMMS / Calibration
Follow your
thought!
Contextual navigation based on the users job function and the task at hand allow real-time
decision making and action
Information that Follows the Asset
Event Information
Mechanical Drawings
What if...Maintenance personnel had consistent access to all alarm information, equipment
data, drawings etc ...
Maint. Report/
Spare Parts Inventory
Active Work Orders
Totally Integrated Maintenance ManagementAsset Condition Monitoring & Maintenance Workflow
AssetMonitor
DTM Asset
Optimization
EmailAlarm
Text message
Isthis Work Order
Already inCMMS ?
DismissFault Report (FR)
YesNo
CMMS
Submit Fault Report
Maintenance Technician
FIX IT!
Schedule
Work Order
© ABB / PA / Control Systems
February 27, 2012 | Slide 18
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Controller Configuration
GraphicsLink to supplier’s site
Column?
What if...Your engineers could configure the plant from pre-defined type solutions containing
all information ...
Fieldbus configuration
© ABB / PA / Control SystemsFebruary 27, 2012 | Slide 20
Integrated Device Management
Real ObjectEach device type object includes aspects for…
Adding a device in System 800xA , you get everything you need for
Device Management, Engineering, Commissioning, Asset Optimization
and even Documentation!!
This is also the case for adding
devices.
Diagnosis
Maintenance Management
Asset Monitoring
Operation
Commissioning
Parameterization
Configuration
Product Documentation
© ABB / PA / Control SystemsFebruary 27, 2012 | Slide 21
Object Oriented Engineering Inheritance is a great thing!
Inheritance ... change an object type once and the change is reflected on each tag made from that instance
System 800xA’s integrated engineering environment lets you
create objects types with much more than just control logic, such as
graphics
If you change object type’s “graphic element”, all tags created from that
object type are automatically updated.
If a graphic element used on numerous
graphics needs to be changed, there’s no need to edit every
graphic.
The next time the graphic is called up, the changes are ready. The dynamics are all the same and were
left untouched.
Reusable Project Solutions
Engineering Efficiency – Reusable Objects ABB’s System 800xA provides a best in class object
oriented engineering environment that maximizes re-use and implementation of standard, proven solutions. Instantiation of object type solutions automatically deploys solution specific requirements to child objects.
Competitors’ engineering approach is usually a ‘template’ solution which is copied and modified for each control strategy. Modifications to these “copies” have to be done individually which increases engineering time, change management complexity, and reduces the ability to enforce project standards, which introduces risk to plant availability and safety.
Business Impact
Improved safety
Improved process profitability and availability and quality
Improved engineering resource utilization
Reduced Overall Lifecycle Costs
Collaboration Network Topology
© ABB Group February 27, 2012 | Slide 24
© ABB Group 3BSE068027 enFebruary 27, 2012 | Slide 24
Information that follows the assetUnique Aspect Objects
© ABB Group February 27, 2012 | Slide 25
Control
Faceplates
Trend
Graphics
Video
Asset Health
Reports
DocumentationERP/ CMMS
Plant centric information access
One Click to all information
Navigation based on job function
Real-time decisions and action
© ABB Group 3BSE068027 enFebruary 27, 2012 | Slide 25
800xA VideoPower of Integration
System 800xA in more detail
800xA Basic Functionality
800xA Operator Effectiveness
800xA Integrated Process and Power Automation
800xA Integrated Safety
800xA Integrated Historian
800xA Integrated Enterprise Asset Management
800xA Integrated Simulation Environment
Summary – 800xA ABB’s collaboration and control system
© ABB Group 3BSE068027 enFebruary 27, 2012 | Slide 26
Aim – Minimize Unnecessary production Loss
Average Dollar Loss By Cause (millions of dollars)
0 20 40 60 80 100
Sabotage / arson
Natural hazard
Unknown
Mechanical failure
Process upset
Design error
Operational error
HPI = Hydrocarbon Processing IndustryFrom HPI Market Data
Source: J&H Marsh & McLennan, Inc
The global process industry loses $20
billion, or five percent of annual production due to
unscheduled downtime and poor
quality. ARC estimates that
almost 80 percent of these losses are
preventable and 40 percent are primarily
the result of operator error.
© ABB GroupFebruary 27, 2012 | Slide 28
Previously
Now
Evolution of process visualizationHuman machine interface
Clear alarming strategy
New, improved graphic elements (e.g. spreads, profiles, color designs, etc.)
Acceptance regions clearly visible
Intuitive, fast navigation
Demonstrable improvements
Human machine interfaceKey components of implementation
Task TraditionalVisualization
High performance Visualization
Results
Recognition of abnormal situations prior to alarm
10% probability 48% probability 5 times faster
Manage abnormal situation
70% 96% 37% higher
Time to clearance 18.1 min 10.6 min 41% faster
Improving Operator Effectiveness Effective decision support environment
© ABB / PA / Control SystemsFebruary 27, 2012 | Slide 30
Consolidated alarms & events Right click
access to integrated information
Seamless integration, and visualization of
actionable information from multiple systems
Event Driven HMI
Operator Effectiveness – 800xA
All information available seamlessly in one system
Operator workplaces for multi screen workplaces and large screens
Pre-integrated ergonomic workstation environment
High performance HMI solutions Intuitive access to actionable information Ability to manage views dynamically and
effectively Reduced time to decision and action
Alarm management (alarm shelving, group alarms and alarms statistics)
Personalized workplaces Point of control Smart client Multisystem integration SMS and email messaging Integrated Process and Power Automation –
One common interface Integrated 3rd party controllers and PLC’s Integrated Live Video (CCTV) with intuitive
access to recorded material Integrated Telecom like voice
communication, public address, TMS etc. Integrated Documentation, maintenance
data and business systems
Where it all comes togetherEOW-x3 Video
Facilitate cooperation by modern control center designStandard workplaces and 3D design tools
© ABB Group 3BSE068027 enFebruary 27, 2012 | Slide 32
SketchUp Virtual Control Room
Promotes Collaboration and ProductivityCommon working environment for many roles
© ABB Group 3BSE068027 enFebruary 27, 2012 | Slide 33
Human FactorsReport
Integrated view of equipment and systemsPowerful workplace and integration
Alarm List
Trend Display Documentation
FaceplateVideo Group Display
Navigation Display Operator Note
The most feature rich operator interface available All information in one window Switch information context with just on mouse click
© ABB Group 3BSE068027 enFebruary 27, 2012 | Slide 34
Streamlining the Operator’s Working SituationBuilt in Alarm Management
EEMUA 191/ISA 18.2 Alarm Hiding
Process state based alarm hiding
Alarm Shelving Operator temporarily removes
alarms from alarm list Alarm Response Navigation
Alarm Analysis Alarm Key Performance
Indicators for alarm system performance
Streamlining the Operator’s Working SituationBuilt in Alarm Management – Alarm Hiding
Streamlining the Operator’s Working SituationBuilt in Alarm Management – Alarm Hiding
Browse or simply write the tag name to define which object to include
Generate consistent documentation in Excel format without effort
© ABB Group February 27, 2012 | Slide 38
Streamlining the Operator’s Working SituationBuilt in Alarm Management – Alarm Shelving
Shelve Alarm
Streamlining the Operator’s Working SituationBuilt in Alarm Management – Alarm Analysis
No of: Active, Unacknowledged, Hidden, and Shelved alarms
Alarm rates and Average, Max number of alarms per hour
Average time to acknowledge alarms
Percentages of alarms above Acceptability level (user defined)
Percentages of alarms above Intense level (user defined)
20 most frequent alarms 20 alarms that were active for the
longest time 20 still active alarms that were
active for the longest time Runtime distribution of alarm
priorities KPIs stored in history - reporting
Top 20 AlarmsTop 20 Longest in
Alarm Alarm Priority Distribution
Active alarms over time
Search and reporting spanning a multitude of systemsCross systems snapshot reports
Create your query, then right click and choose requested information.Used at shift change or during maintenance etc.
© ABB Group 3BSE068027 enFebruary 27, 2012 | Slide 40
Operator Environment Supporting ProductivityAll built based on with ergonomics in focus
The best operator environment available
Offering a truly attractive and ergonomic Collaboration Environment
Based on standard Products© ABB Group 3BSE068027 enFebruary 27, 2012 | Slide 42
System 800xA in more detail
800xA Background
800xA Basic Functionality
800xA Operator Effectiveness
800xA Integrated Process and Power Automation
800xA Integrated Safety
800xA Integrated Historian
800xA Integrated Enterprise Asset Management
800xA Integrated Simulation Environment
Summary – 800xA ABB’s collaboration and control system
© ABB Group 3BSE068027 enFebruary 27, 2012 | Slide 43
Promoting CollaborationIntegrated Process and Power Automation
Process Automation Process Electrification Power Distribution
One unified approach to increase productivity and decrease downtime and maintenance cost
© ABB / PA / Control SystemsFebruary 27, 2012 | Slide 44
Process and Power Automation in the pastA large integration challenge
Poor working procedures Organizational barriers among
process and power department Separate system for power
automation Lack of visibility
Lack of information from electrical devices
Many protocols, lack of global standard
Cost drivers A lot of hardwiring needed Old fashioned network equipment Device specific solutions of
integration into DCS
© ABB Group 3BSE068027 enFebruary 27, 2012 | Slide 45
Control Room
Control System
Control
Process
Protection & Control IEDs
Promoting CollaborationIntegrated Process and Power Automation
Controller
Plant Network
Controller
Profibus/Profinet
Substation Automation
Process Control Server
IEC 61850
Process & Power Workplaces
Instruments
LV SwitchgearDrives Motor starters
ProcessElectrification
ProcessInstrumentation
Plant-wide Sequence of
Events for better root cause analysis
Same operations interface and
engineering for shared information and
knowledge
Centralized Historian and
Data Archiving
Centralized Historian and Data Archiving
Common, integrated asset management
strategy
Electrical integration based
on Open Standards such as IEC 61850, Profinet/Profibus…
Electrical integration based
on Open Standards such as IEC 61850, Profinet/Profibus…
Common system therefore reduced
spare parts, training etc…
Standardized procedures, settings, control logic and
libraries
Standardized procedures, settings, control logic and
libraries
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Unified Operations and Common PlatformBased on 800xA Extended Automation System
Greater flexibility in operation of the facility Electrical dispatcher inhibits a breaker and connected loads on Process side get
blocked from operation (Picture below)
Safety & Data Security Access Control to avoid non-authorized intervention in operation of electrical
equipment
Process Operator View Electrical Dispatcher/Operator View
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Distribution1 Safety equipment 11,7 %2 Electric power distribution 11,3 %3 Instrumentation 10,6 %4 Piping specialities 8,7 %5 Lifting 8,1 %6 Pressure vessels and storage tanks 5,7 %7 Piping, pipeline, risers and umbilical 5,0 %8 AC, equipment for refrigeration 5,0 %9 Turbines 4,4 %10 Manually operated valves 4,2 %11 Pumps 3,8 %12 Power generation/transformation 3,8 %13 Communication equipment 3,1 %14 Other 3,1 %15 Safety relief valves 3,0 %16 Combustion engines 2,6 %17 Actuator operated valves 0,9 %18 Not relevant 5,2 %
100,0 %
Planned Maintenance by Asset *Class* North Sea Platform example
Typical scope for Asset Management Tools
Extending Asset Management into electrical
equipment
Customer BenefitsOptimized Maintenance Strategy
Monitoring
Reporting
AnalyzingDecision
ActionSubmit
Control network
Client/Server network
IEDs for Bay Protection, Generator Protection, Transformer Protection,Motor Protection…
IEC61850 network
IEC61850 GOOSE
IEC61850MMS
Workplace
Operator Workstation
Integrated Process and Power AutomationElectrical Integration – IEC61850
Up to 80 Per Network
Engineer Workstation Firewall to Enterprise Layer
System 800xA
AC 800M “IED”HorizontalIntegration
IEC61850 OPC server
VerticalIntegration
PMS Application
© ABB Group
February 27, 2012 | Slide 50
What does the PMS offer
Configurable Solution
Network Determination
Load Shedding
Power Control
Generator Control
Synchronisation
Breaker Control
Motor Control
Tap Changer Control
1ms Resolution on system events
Integrated Process and Power AutomationElectrical Integration – Power Management Solution
Vertical/Horizontal Communications
Load Shedding
Integrated Asset Management
Access to Disturbance Records
Access to Disturbance Records
Parameterise the IED
System 800xA in more detail
800xA Basic Functionality
800xA Operator Effectiveness
800xA Integrated Process and Power Automation
800xA Integrated Safety
800xA Integrated Historian
800xA Integrated Enterprise Asset Management
800xA Integrated Simulation Environment
Summary – 800xA ABB’s collaboration and control system
© ABB Group 3BSE068027 enFebruary 27, 2012 | Slide 57
Promoting CollaborationIntegrated Process Control and Safety
Plant-wide Sequence of Events
Same operations interface and engineering
Centralized Historian and
Data Archiving
Centralized Historian and Data Archiving
Common, integrated asset management
strategy
Common system therefore reduced
spare parts, training etc…Process control
and safety in the same HI controller Centralized
Historian and Data Archiving
Process control and safety running in
separate controllers
Powerful Safety EngineeringEfficient working methods
One uniform engineering environment Process and Safety engineering done in
the same tool
One engineering documentation set
Protection of SIL classed functions Download prohibited if SIL requirements
are not fulfilled
Confirmed on-line write (HMI)
Firewall mechanisms
CRC protection on several layers
3
© ABB Group 3BSE068027 enFebruary 27, 2012 | Slide 60
800xA Integrated Safety is proven world-wideInstalled Base
Proven in use
30 years of experience of integrated safety
1,000 AC 800M HI controllers in operation
1,000 more safety controllers in the project pipeline
ABB project organizations all over the world certified for safety engineering
© ABB Group 3BSE068027 enFebruary 27, 2012 | Slide 61
System 800xA in more detail
800xA Basic Functionality
800xA Operator Effectiveness
800xA Integrated Process and Power Automation
800xA Integrated Safety
800xA Integrated Historian
800xA Integrated Enterprise Asset Management
800xA Integrated Simulation Environment
Summary – 800xA ABB’s collaboration and control system
© ABB Group 3BSE068027 enFebruary 27, 2012 | Slide 62
© ABB Group
February 27, 2012 | Slide 63
3-rd PartyHarmony
Advant
Data Collector
800xA HistoryDeployment Architecture
TPPS Server(s)
AC800 M
Connectivity Server
Client Server Network
Third Party Server(s)Connectivity Server(s)
Plant Information Network
800xA History
Data Collector
DCN
Data Collector
DCNCombined CS + DCN
-Data collection -buffer collection-fault tolerant
- real-time values- raw history + aggregates- alarms and events-calculations-data access
ODBCOPC DA & HDA
DCN
Control Network
DCN
DCN
3-rd Party
Production Report Event Report….Reports/Data Access
Standalone DCN
Secured, Encrypted and Compressed data transfer
High performance historian engine Cyber-secure data collection with
redundancy Firewall friendly communication Seamless history access in
System 800xA platform Ease of engineering/Single point
configuration
800xA History Features
Controllers
Plant Network / Intranet / Internet
800xA Smart Client
Controllers
Router / Firewall
Router / Firewall
800xA History
Data Collector Data Collector
© ABB Group
February 27, 2012 | Slide 65
Common Engineering
Log Configuration Aspect
Current History Log
Aggregate Log
External Log
Bulk Import Tool
Automatic One-Time Configuration
Automatically maintain History tag definitions so they match System 800xA data points
Tag synchronization automatically builds the History database from the System 800xA log configuration
Changes to the System 800xA points are automatically sent to History when they occur, reducing administration and maintaining the integrity of the database
Tag Definitions are Accurate
Updated on a timely basis
Kept current without manual intervention
Automated Tag Synchronization
System 800xA in more detail
800xA Basic Functionality
800xA Operator Effectiveness
800xA Integrated Process and Power Automation
800xA Integrated Safety
800xA Integrated Historian
800xA Integrated Asset Management
800xA Integrated Simulation Environment
Summary – 800xA ABB’s collaboration and control system
© ABB Group 3BSE068027 enFebruary 27, 2012 | Slide 66
Asset Management Industry Facts and TrendsIndustry facts
In the past many companies viewed maintenance as a necessary evil
Traditional maintenance practices result in lower return on assets
Corrective and scheduled maintenance
Instrument unavailability
Inefficient work processes
Today it is viewed as a strategic opportunity In North America, Over US$20 Billion, or
almost 5% of total production is lost each year due to unscheduled downtime.”
– ARC Insights
© ABB Group 3BSE068027 enFebruary 27, 2012 | Slide 67
Maintenance Saving PotentialEfficient working methods
Current methods at hand1. Corrective: On failure (55%)
2. Preventive: On schedule (35%)
3. Predictive: On condition (10%)4. Reliability centered: Mix the above based
upon the role of the individual asset and its safety and criticality status
© ABB Group 3BSE068027 enFebruary 27, 2012 | Slide 68
Throughput
Time
Partial shut-down
Plant upset
Shut-downStartup
Reliability Centered Maintenance (RCM) Focus on criticality of equipment
Apply the technique that is appropriate based upon the criticality of the equipment
Blend of maintenance techniques
Reactive
Preventive
Predictive
BEP
Typical ~55%
~31%
~12%
Improvement Potential with 800xA Tailor conditions based upon criticality and severity
World Class <10%
25%-35%
45%-55%
Facilitating Predictive Maintenance Reduced down-time requirements for Maintenance
Reduced maintenance cost on devices that did not need attention
Reduced Time to Repair Diagnostics aids, Recommended actions readily available
Documentation and Standard Operating Procedures one click away
Streamlined maintenance workflow Integrated maintenance procedure, calibration and CMMS
No manual data entry errors, paper work reduction,
Facilitating Proactive Root Cause Elimination Identifying “repeat” offenders
Failure Avoidance Detecting conditions leading to failures in advance allowing for corrective action
prior to failure
The Objectives of Asset Management
Cost saving over the whole asset life800xA Integrated Asset ManagementSavings
Maintenance savings thanks to reliability centered procedures
Same system and HMI for all assets means one common set of tools, working methods and documentation
Supervision of
Process equipment health
Electrical equipment health
Automation system and IT infrastructure health
Performance
Run-time
DeviceData
AssetCondition
AssetMonitor
MaintenanceCondition
MaintenanceWork Order
Fault Reportin CMMS
© ABB Group 3BSE068027 enFebruary 27, 2012 | Slide 71
System 800xA Integrated Enterprise Asset Management
ISA-S95 defines Level 3 Maintenance scope
CMMS integration and Calibration Integration
Ventyx and Mincom products and services
ABB Integrated OperationsEnabling Predictive Maintenance
“Predictive maintenance saves time and energy. Studies indicate that a proper predictive maintenance program saves between 8% and 12% more than a purely preventive maintenance program. In fact, the following average savings are typical within industrial settings:
Return on investment: Up to 1,000%Reduction in maintenance costs: 25% to 30%Elimination of breakdowns: 70% to 75%Reduction in downtime: 35% to 45%Increase in production: 20% to 25%”
Source: US Department of Energy (http://www1.eere.energy.gov/femp/program/om_predictive.html)
Condition Monitoring System…more than instruments
© ABB Group February 27, 2012 | Slide 74
Rotating Equipment Valves Instrumentation Static Equipment
Metering Electrical HVAC F&G Detectors
Subsea Marine Analyzers Telecommunication
Performance Control loop IT Equipment …
System 800xA– Asset Monitor Portfolio
Basic AM
Ass
et M
onito
r Por
tfolio
Field-device AM
PC, Software & Network AM
Control Network AM
Machine AM
Plant Performance AM
ElectricalEquipment AM
Plant Equipment AM
3rd Party Integration AM
Pumps, compressors, … Motors, Control loops, …
ABB Harmony ABB AC800M ABB Melody Servers, Clients Switches, Printers, …
HART, Profibus, Fieldbus FOUNDATION ABB devices 3rd party: Metso, Yokogawa, E&H, …
High/Low Limit supervision for signals Runtime check, event counter OPC Quality & Boolean check
IEDs, Motor controllers, motor starters LV, MV Drives Switches, …
Heat-exchangers, … Control loops, …
RealTime Production Intelligence AM Plant-wide disturbance
Condition Monitoring Tools (SystemOne, PumpExpert, …)
© ABB / PA / Control SystemsFebruary 27, 2012 | Slide 753BUS095244 en
800xA Asset Optimization
Asset Condition Monitor
Critical Asset Alarm List
Fault Report Viewer
Fault Report Submitter to
CMMS
Network and PC Asset Monitoring
800xA System Asset Optimization
Control Loop Asset Monitor
Heat Exchanger Monitoring
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Integrated Electrical Asset ManagementLow Voltage MCC integration - Profinet
Proactive: “Operating Hours Alarm”
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Integrated Electrical Asset ManagementMV/HV feeder protection IED – IEC 61850
REF615 Condition Monitoring Functions Circuit Breaker Status
Operation Monitoring Time
Breaker Contact Travel Time
Operations Cycle Counter
Spring Charge Indication –accumulated energy
Breaker Wear – remaining life of the breaker
Accumulated Energy
Gas Pressure Supervision
ABB Integrated OperationsRealizing the value of a modern maintenance strategy
Situation: Gradually evolving fault with a critical machine
ABB Integrated OperationsRealizing the value of a modern maintenance strategy
Asset Monitor sends alarm to operator, actions are taken immediatelyto avoid a shutdown while critical maintenance is planned
ABB Integrated OperationsRealizing the value of a modern maintenance strategy
Maintenance strategy has identified this machine as critical, and additional instrumentation is included in the design. Combined effect of temperature and vibration causes the Asset Monitor/Equipment Monitor to flag a maintenance event. This event initiates a workflow where onshore experts diagnose the machine and generate a rapid maintenance work order
ABB Integrated OperationsRealizing the value of a modern maintenance strategy
Performance monitoring system has detected a declining performance and flags this to the centralized maintenance support crew. After conferring with operations and receiving on-line support from the OEM’s, the problem is diagnosed and maintenance is rescheduled to be performed at the earliest opportunity
ABB Integrated OperationsRealizing the value of a modern maintenance strategy
The operator has a centralized predictive maintenance support team that monitors all critical machines. Using information from several sources (Drive Monitor, vibration monitor, performance monitor, operator observation), the potential problem is flagged in a very early stage. A regular maintenance shutdown is used to fix the problem .
ABB Integrated OperationsRealizing the value of a modern maintenance strategy
An active maintenance strategy with structured work process and modern tools enables early fault detections, reduces costs and avoids expensive breakdowns
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Messenger service sends messages with alarm information to pagers, email accounts, and SMS/GSM devices configured to receive them
Configurable user groups assign messages to specific individuals or groups
Message handler allows specification of source and destination, time to wait for acknowledgement before resending, and number of attempts before changing destination
Message scheduling allows configuration of times that each user receives message
Remote Alarming to Key Plant Personnel
Common Notification Framework with System 800xA
System 800xA in more detail
800xA Basic Functionality
800xA Operator Effectiveness
800xA Integrated Process and Power Automation
800xA Integrated Safety
800xA Integrated Historian
800xA Integrated Asset Management
800xA Integrated Simulation Environment
Summary – 800xA ABB’s collaboration and control system
© ABB Group 3BSE068027 enFebruary 27, 2012 | Slide 90
© ABB ASFebruary 27, 2012 | Slide 91
IndustrialIT Training SimulatorSystem 800xA used for training and testing
Increased safety and productivity
Lifecycle simulator
System 800xA extended with simulator functionality Realistic training and test
environment
Runtime Simulation Functions
Interfaces independent of model vendor
Engineering
Easy configuration and maintenance
Proc
ess
Mod
el &
Inst
ruct
or S
tatio
n
I/O simulation ITS Link
Sim
ulat
or
Con
trol
roo
m
Soft Controllers
Plan
t C
ontr
ol r
oom
Proc
ess
AC
800
M
System 800xA
Plant system Simulator system
Cost-effective, comprehensive process simulator reduces start-up time and costs, assure longer life,
and lower lifecycle costs
© ABB ASFebruary 27, 2012 | Slide 92
Control systemSoft ControllersSimulate I/OOPC DA
Runtime Simulation Functions
IndustrialIT Training SimulatorRealistic Training and Test Environment
System 800xAconfiguration
Proc
ess
Mod
el
I/O ITS Link
Sim
ulat
or
Con
trol
room
Simulator system
Soft Controllers
AC 8
00M
Plan
t C
ontr
ol ro
omPr
oces
s
AC 8
00M
AC 8
00M
AC 8
00M
AC 8
00M
Plant system
Inst
ruct
or S
tatio
n
© ABB ASFebruary 27, 2012 | Slide 93
IndustrialIT Training Simulator Realistic Training and Test Environment
Update with System 800xA configuration Use standard tools to transfer
configuration for 800xA and control system
Identical operator environment Faceplates, displays, Alarm &
Event lists, trends
Physical I/O for operator panels and switch boards
Identical control logic environment Execution and Engineering tools
Runtime simulation functions
Simulate I/O through a dynamic process model
Identical operator environment
Identical control execution
System 800xA in more detail
800xA Basic Functionality
800xA Operator Effectiveness
800xA Integrated Process and Power Automation
800xA Integrated Safety
800xA Integrated Historian
800xA Integrated Asset Management
800xA Integrated Simulation Environment
Summary – 800xA ABB’s collaboration and control system
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Meeting the Challanges
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People
EquipmentSystems
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System 800xA – Our customers Collaboration System
Welcome to The Power of Integration!
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System 800xA – Is widely usedProven in use System 800xA has been delivered in over
100 countries
In 7 years we have sold:
8,000 800xA systems
Over 52,000 AC 800M controllers (since Jan 2004)
Over 35,500 Operator workstations (since Jan 2004)
Over 27 million S800 I/O channels
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System 800xA – The market leaderLeading supplier of DCS systems world wide
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2010 2009 2008ABB 21,8 21,4 18,2Siemens 15,1 15,6 16,7Honeywell 13,1 13,2 14,1Yokogawa 12 11,7 11,8Emerson Process Management 10,7 11,4 11,1Invensys 6,9 7 10,9Rockwell Automation 3,6 3,5 3,2Alstom 2,7 2,6 2,1Yamatake 2,2 2,2 2
Source: ARC 2010 DCS World Wide Outlook (September 2011)
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© ABB Group February 27, 2012 | Slide 100