Industrial IT System 800xA

High integrity automation solutions for

continuous productivity improvements

System Description

Extended Automation System 800xA

© ABB - Page 1
 Traditional Automation

Programmable
Logic Control

Motor Control
Centers
Asset Optimization

Information S88 Production

Management “Traditional” Management

DCS/OCS
© ABB - Page 2

Advanced Control

Instrumentation Safety
& Drives
 Extended Automation – Redefining the Standard
Redefining the Automation
System Standard

A single operations, engineering and

information management environment for
an Extended Automation scope
© ABB - Page 3
 Achieved by extending your existing OCS to a System 800xA …

“Traditional”
ABB DCS/OCS

IndustrialIT System
Enhancements
© ABB - Page 4
 …or by building a new system by applying System 800xA
© ABB - Page 5
 System 800xA – Your Competitive Advantage
System 800xA extends the reach of traditional DCS --
including production management, safety, discrete, and
advanced control, information management, smart
instrumentation, smart drives and motor control centers,
asset management, and documentation management
capabilities – to achieve the productivity gains
necessary to succeed in today’s business markets.

System 800xA integrates and aggregates real time data,

providing information and tools to advise and analyze, and
facilitates action in the new, expanded automation
environment to help you achieve continuous
© ABB - Page 6

productivity improvement
 Continuous Productivity Improvement Themes

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
Improving Batch Production
Profitability, Consistency, and
Traceability
Investment Enhancement through
Evolution
Proven Solutions based on Industry
Knowledge and Experience
© ABB - Page 7
 Continuous
Productivity Reducing Time to Decision and Action
Improvement

Make it easy for the right people to get the right

information at the right time
Personalized workplaces based on function and
requirements
Immediate, intuitive access to relevant information
and data
Integration of disparate sources of data into a
single window
Comprehensive operator functionality
Examples:
Alarm Management
SMS Messenging
Trending
Reporting
© ABB - Page 8
 Continuous
Productivity Reducing time to Decision and Action
Improvement

Personalized workplaces for operations, maintenance,

engineering, management
Navigation in a context appropriate to job function provides
quicker access to the information required
Ability to combine and interpret information from disparate
systems in one place
Redefine the use of the traditional “operator station”
Predefined, flexible, information content and context
© ABB - Page 9
 Continuous
Productivity Reducing time to Decision and Action
Improvement

Single-Click Access to Relevant Data

Integrated Documentation Access
Examples: standard operating procedures, technical manuals,
P&ID s, loop drawings
Asset Condition and Management Information
Examples: plant asset status, work order history, calibration
information, spare parts inventory
Real-Time and Historical Data
Examples: real-time/historical trends, snap-shot/query/production
reports, audit trails
Visual information
Live video, training videos
© ABB - Page 10
 Continuous
Productivity Reducing time to Decision and Action
Improvement

Comprehensive Operator Functionality

Event / Need for Action Notification
Alarm & Event notification
Audible notification via .wav files
Text messaging, pagers, and email notification
Composite asset condition status views
Action Facilitation
Telephone / Contact lists
Standard Operating Procedures (SOP)
Recommended actions
Maintenance instructions
© ABB - Page 11
 Continuous Productivity Improvement Themes

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
Improving Batch Production
Profitability, Consistency, and
Traceability
Investment Enhancement through
Evolution
Proven Solutions based on Industry
Knowledge and Experience
© ABB - Page 12
Engineering for
Maximum
Performance What Are The Problems ?
Multiple configuration tools and
systems are required to manage
the entire plant lifecycle
Data inaccuracies
Information not widely accessible
Maintenance is complicated
Additional training required
Need to do more with less
Cost reductions
Fewer resources
75% of automation solutions costs
come from engineering, testing,
and documentation.
© ABB - Page 13
Engineering for
Maximum
Performance 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
© ABB - Page 14
 Continuous Productivity Improvement Themes

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
Improving Batch Production
Profitability, Consistency, and
Traceability
Investment Enhancement through
Evolution
Proven Solutions based on Industry
Knowledge and Experience
© ABB - Page 15
 System 800xA
Safety 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
© ABB - Page 16

Embedded safety and process control

 System 800xA
Safety 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
© ABB - Page 17

Embedded safety and process control

 System 800xA
Device Management High Plant Availability

The 800xA system provides high

availability through redundancy at
all levels:
Controllers
Remote I/O
Linking Devices
Cables
Servers and workplaces
A wide range of SIL-rated HART
sensors, valve positioners, and
actuators
Large portfolio of intrinsically safe
fieldbus components for
installation in hazardous areas
Fieldbus Solutions to Meet
all Plant Requirements
© ABB - Page 18
 System 800xA
Safety Meets industry standards
Among others, 800xA Safety systems
are delivered and support in according to
the following standards
IEC 61508
IEC 61511 – Process Industry
EN 954 / IEC 62061 - Machinery
NFPA 85 – Combustion US
NFPA 72 – F&G US
In addition to guidelining product
requirements, these standards specify
TÜV Product Service, the
foremost independent procedures and routines for all activities
certification agency in the required to manage safety throughout
business, has certified all the entire lifecycle of the system.
product components on the
800xA Safety offering Includes planning, design,
implementation, documentation, training,
operation, and maintenance.
© ABB - Page 19

Complete SIL
Compliant SIS Solution
 Continuous Productivity Improvement Themes

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
Improving Batch Production
Profitability, Consistency, and
Traceability
Investment Enhancement through
Evolution
Proven Solutions based on Industry
Knowledge and Experience
© ABB - Page 20
 System 800xA
Asset Optimization Fast, Reliable Implementation of Actions
Real-time monitoring of plant asset Key
Performance Indicators (KPI) keep
“score” of asset performance
Plant resident information used to
determine performance
Scheduled monitoring of asset health
status via “asset monitors”
Pre-configured asset monitors exist Automatic Monitoring
for wide range of assets: of Maintenance
Basic asset functions Conditions and
Field devices (HART, PROFIBUS, Automatic Alarms
Fieldbus FOUNDATION)
Electronic equipment
PC, network, and software
© ABB - Page 21
 System 800xA
Asset Optimization Fast, Reliable Implementation of Actions
Reporting and analysis
visualization via Maintenance
Workplace
support determination of root
cause
Event driven generation of asset
conditions reported to:
800xA Alarm and Events
Animated Asset Viewer reports
most severe maintenance
Consistent
condition
V-1
LC Serv
01 ce
i reporting of plant
Remote viewing using standard Ou
t o f
asset health status
web technology
Remote notification via Email
and/or paging
© ABB - Page 22
 System 800xA
Asset Optimization Streamlined Remediation Work Processes
Corrective action taken.
Operator notified asset
problem corrected
Problem identified by

n
Asset Monitor

e e
Work order automatically added

e t w
and scheduled in CMMS (If
e
b n c
calibration required, work order is
n
o ten a
forwarded to DMS Action List)
i
a c t n
t e r a i
in d m Submit fault

e s s a n report to CMMS

m l ns
ea t i o
S era
op Reduced time to repair through
© ABB - Page 23

optimized work processes

Is CMMS aware of problem?
Has maintenance been scheduled?
 Optimizing Plant
Asset Availability
And Performance Asset Optimization improvements
Performance Improvements
Asset Viewer and Asset Reporter
Reduced startup time for Asset Monitoring
Colored frame indicates information reliability
The accumulated Asset Status moves down the tree
to the source while the user unfolds the structure
AO Alarm Category
Filtering on Asset Condition alarms only
Enhancements
Asset Monitoring
Asset Monitor execution triggered
by OPC Alarm and Event Data sources
Asset Monitor Library Expansions
Control Loop Asset Monitor
Counter Check AM
Heat-Exchanger Asset Monitor
System Status Asset Monitor
MAXIMO Integration
Support of MAXIMO 5.2 added
SAP/PM integration
© ABB - Page 24

Portal Views allow navigation from workorder entry in 800xA directly to the related
information in SAP/PM thin client view
 Continuous Productivity Improvement Themes

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
Improving Batch Production
Profitability, Consistency, and
Traceability
Investment Enhancement through
Evolution
Proven Solutions based on Industry
Knowledge and Experience
© ABB - Page 25
 Integrated
Information for
Improved
Visibility
System 800xA Information Management

Data Collection, Storage, and Benefit

Consolidation
Data Collection, Storage and Knowledge
Consolidation from across the
scope of automation
Information
Transformation
Transformed data into meaningful, Data
actionable information (KPIs - Key
Performance Indicators)
Visibility and Access
Customized views and reports for
various plant personnel
Open Data Access to System
800xA data.
© ABB - Page 26
 System 800xA
Information
Management Intuitive Presentation

Operator trend
displays
Web-based viewing
of information
Desktop trend
displays
Desktop tag ticker
display
All data integrated
into a single display
System data viewing
with Microsoft Excel
Historical events Timely decision making based on
displayed with concise, real time presentation of the
flexible filtering
© ABB - Page 27

relevant information
 System 800xA
Information
Management Automated Actions

Actions
Data Collection
Calculations
Reports
Archiving
Data consolidation
System back-up
Action triggers
Event-driven
Time-based
Cyclic (e.g end of shift )
Automating critical system activities
On demand
© ABB - Page 28
 System 800xA
Information
Management Flexible Report Generation & Distribution

Real time data, historical

values, lab data, batch
information and event
information
Microsoft Excel,
Crystal Reports
Report destinations
Printers
e-mail
Historical storage
Local or network disc
storage
Full documentation and planning support
through streamlined reporting in the
appropriate format and media
© ABB - Page 29
 Continuous Productivity Improvement Themes

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
Improving Batch Production
Profitability, Consistency, and
Traceability
Investment Enhancement through
Evolution
© ABB - Page 30
 System 800xA
Production
Management 800xA Batch Management
Batch Management is a comprehensive batch
automation solution for:
Configuring recipes and
procedures
Configuring batch equipment
Scheduling, monitoring and
controlling batches and
campaigns
Automatic arbitration of
resources between batches at
runtime
Collecting and storing batch
historical information
© ABB - Page 31
 System 800xA
Batch
Management Flexible Recipe Management

Reusable recipe building

blocks follow S88 batch
control standard
Runtime display of control
recipes provides operator
current status information
Supports on-line changes to
control recipe without
suspending the batch
Exception procedures
provide recipe-driven error
handling capability

Improves production yields,

minimizes scrap, and improves
overall production profitability.
© ABB - Page 32
 Continuous Productivity Improvement Themes

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
Improving Batch Production
Profitability, Consistency, and
Traceability
Investment Enhancement through
Evolution
© ABB - Page 33
 System 800xA
Architecture Scalable and Flexible

Extended functionality doesn’t 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.
© ABB - Page 34

Cost-effective Design
 System 800xA
Architecture Scalable and Flexible

Typical
Small
Typical
Large

Cost-effective Design Redundancy at all levels

Application servers
Client / server network
Connectivity servers
Control network
Controllers
© ABB - Page 35

I/O
Fieldbus
 System 800xA
Architecture Typical “Small” System

One single PC
Aspect server
Connectivity server
Rich client
Windows XP Professional
Up to 1000 process I/O
1..3 controllers
10Mbit/s Control network
© ABB - Page 36
 System 800xA
Architecture Typical “Large” Configuration

Redundant Aspect servers

(1oo2 or 2oo3)
Redundant Connectivity
servers
Separate nodes for Batch
server(s), IM and AO servers
Up to 40 Rich clients
Up to 30 Remote clients
Up to 75 controllers
Redundant 100Mbit/s Control
network and Client/server
network, with suitable
sectioning by use of switches
© ABB - Page 37
 Investment
Enhancement
Through Evolution Integration improvements

Connectivity’s
800xA for Advant Master
Increased system size: up to 4 single/redundant CS pairs/MB 300 network
Support for 800xA common alarm list
Common alarm icon in faceplates
Small system support - Combined AS+CS together with AC 800M Connect
Support for PCs with hyper-threading/dual CPU
800xA for Harmony
Batch integration - chemical/life science market
Harmony System Diagnostic Displays
Advanced Harmony Control System Monitoring
Harmony tag objects support for Hot keys
Small system support - Combined AS+CS w/ 30k tags
Expanded mixed system support; Harmony w/ MOD300 and Master
Multiple Harmony Configuration Server support
Prefabricated cables between INFI 90 Rack I/O TU and S800

800xA for MOD300

Batch integration – chemical/life science market
Support for PCs with hyper-threading/dual CPU
Small system support - Combined AS+CS
Improved audit trail capabilities
© ABB - Page 38

Support for 800xA common alarm list

Common alarm icon in faceplates with both AC800M and AC460
Prefabricated cables between existing termination panels and S800
 Investment
Enhancement
Through Evolution Integration improvements

Connectivity’s continued
800xA for Freelance 800F (subject to separate release)
Support of Hardware Diagnostic information in Control Structure
Migration for DigiBatch users to 800xA Batch via Function Phase Driver for PLI-
function block
Support for mixed system of Freelance 800F and AC 800M

800xA for DCI

Batch integration
Support for Audit Trail
Small system support - Combined AS+CS

800xA for Melody, 800xA with AC 870P

Support for 800xA common alarm list
Support of priority mapping
Support of common SFC viewer
Small system support - Combined AS+CS
Combined Composer Server and Config Server up from CSV 5.0 (TSA needed)
Mixed system support with AC 800M
© ABB - Page 39

PLC Connect
Automatic filtered upload of OPC server contents
Communication line redundancy with slave server on hot standby
Support of Composite Object Types
 Reducing time to decision and action

Operations

Extended Automation System 800xA

© ABB - Page 40
 System 800xA
Operations Presenting Relevant Information
Management
Operator Workplace
Workplace
Maintenance Workplace
Different workplace layout adjusted to
individual preference and needs
Operator
Advanced Operator
Maintenance
Engineer
Plant Manager
Menu and toolbar content focused
towards individual user
Favorites
User specific context menu items Personalized workplaces for
(i.e. Engineer access to control
strategies while operator cannot) focused information access
User profile based upon security log-in
Log-over
Authentication
© ABB - Page 41
 Reducing Time
To SV 5.0
Decision & Action Operator Workplace improvements

View handling and Navigation

Quad Display with zoom
Select frame around graphical element
Object lock to reserve objects
Replacement strategy for overlap
displays
Improved Multi-screen support
© ABB - Page 42
 Reducing Time
To SV 5.0
Decision & Action Operator Workplace improvements
Multi-screen support
Preconfigured templates for two,
three and four screens available on
installation media
Multiple Screen
Large Workplace
Support for 1280x1024 and
1600x1200 pixel resolution
© ABB - Page 43
 Reducing Time
To SV 5.0
Decision & Action Operator Workplace improvements
Possible to send aspect window to
other node and workplace
Graphics on one regular monitor can for
instance be sent to a large overview
screen
Base display always on screen
where it is called from
© ABB - Page 44
 System 800xA
Operations Quick Response to Plant Conditions

Consistent call-up using the right mouse

button
Display and document call-up
References to all process graphics where
object is represented
Action verb (i.e. acknowledge alarm)
Single click access to displays and
information
Display links
Short cuts
Favorites
Back and forward buttons Intuitive and flexible navigation
History lists for fast information access
Programmable hot keys
Access via structured hierarchy
Functional structure
Control Structure
…
© ABB - Page 45
 System 800xA
Operations Addressing Mainstream Operator Needs
Extensive operator functionality
Alarms and Events
Multiple presentations including
alarm lists, alarm bands, and
alarm lines
Configurable sorts and filters
Reporting
Scheduled, on-demand, and
event triggered
MS Excel and Crystal reports
Messenger
Remote notification and
acknowledgement
GSM, E-mail

Comprehensive operator
functionality for reliable control
© ABB - Page 46
 System 800xA
Operations Successful operations worldwide

Collahausi Mining Company,

Patache Port, Chile
Hydro, Grane Crude Oil
Terminal, The North Sea

Korea District Heating

Corporation, Gangnam,
Anhui Conch Cement Korea
Company Limited, China
© ABB - Page 47

East Province Cement

Company, Saudi Arabia
Södra Cell, Mörrum Pulp Mill,
Sweden
 Engineering for maximum performance

Engineering

Extended Automation System 800xA

© ABB - Page 48
 System 800xA
Engineering
Easy Navigation and Consistent Data
Plant Explorer with Objects and Aspects

A single, intuitive user interface

bringing together all plant
information
Easy navigation via context
menus
One-time data entry
Providing single source of
accurate and current plant Dimensional Drawing
information results in
Maximum engineering Process
Engineering
performance Diagram
Better quality
High reliability

Main
Faceplate
© ABB - Page 49

Integrated engineering environment

Function
 Distributed Engineering
Flexible cooperation in work groups:
On-site Engineering
A multi-user on-site environment
A variety of tasks are performed and
applied to the automation system
simultaneously
Off-site Engineering
Integrate distant co-workers for
isolated tasks
Synchronize results when
appropriate
Benefit:
Optimized environment for
engineering teams
© ABB - Page 50
 From Sensor to the Valve
© ABB - Page 51
 All in the same Diagram

Description Text Functional Design

HART Device DTM Autom. Generation of Variables

© ABB - Page 52

Documentation Bitmap Import

Controller + I/O
Footer
 Intuitive Navigation
Reference to other function

Reference to other sheet

© ABB - Page 53

Reference to nested function

 System 800xA
Engineering Create Customized Operator Graphics

Easy customization of
operator graphics using a
comprehensive library
Standardized faceplate
concept minimizes
configuration time

Process visualization
© ABB - Page 54
 SV 5.0
Next Step
Multisystem Integration

1. Geographically separate 800xA systems with local control

rooms to be controlled from a common control room
2. Sectioning of multiple line processes to increase integrity and
simplify maintenance
3. Making staged commissioning without interfering with running
processes possible
Central Control room
Local control rooms

800xA 800xA 800xA

© ABB - Page 55
 Integrating
Information for
Improved Visibility Multisystem integration structure

Multisystem Integration makes it possible to view and

operate objects configured in one system from another
system
Targeting Operator related functionality
Subscriber

System D

System A System B System C 1…10

Provider Provider Provider

© ABB - Page 56

Note: Only AC 800M controllers are supported in Provider system(s) with SV5.0 SP1
 Control and I/O to meet all
automation and safety needs

AC 800M
Control & I/O

Extended Automation System 800xA

© ABB - Page 57
 System 800xA
Control & I/O 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
S900 I/O (Ex)
© ABB - Page 58
 System 800xA
Control & I/O Control System Availability

Designed for use in harsh

industrial environments
Redundancy at all levels
On line configuration
and maintenance

Fault tolerant design for

maximum plant availability
© ABB - Page 59
 S800 I/O
Installation Modular three part design
Fieldbus Communication Interface (FCI)
PROFIBUS-DPV1, also redundant
HART pass-through
Hot Configuration in Run
Power distribution to I/O modules
I/O module
Full range of signal types including AI, AO, DI, DO,
Temp, Pulse, Freq, HART, IS interface, SOE
Hot-swap
Redundancy
Termination unit (TU)
2-wire Compact design
3-wire Extended design, also with fuses
© ABB - Page 60

Mechanical key and locking/activation tab

 S800 I/O
Installation Distribute the I/O as you like

Direct I/O to AC 800M

Remote distribution using

PROFIBUS

Optical link distribution

from AC 800M (clusters)
Also long distance (~1000m)
in star configuration
© ABB - Page 61
 S800 I/O
Highest availability

Hot Configuration In Run

Hot Swap of I/O modules

OSP, Outputs can be Set to a

Predetermined value in
case of malfunction

Built in diagnostics, LED's and

cyclic data security
© ABB - Page 62

Redundancy on all levels

 S800 I/O
Availability Re-configure online
Configure the I/O on-line when connected as Direct I/O to
AC 800M
Hot Configuration in Run is supported on PROFIBUS
Valid for parameter changes
Possible to add or delete I/O modules
Pre-install termination units to prepare for adding modules
© ABB - Page 63
 S800 I/O
Availability Hot-swap of modules at any time

Hot-swap means that a module can be

replaced without disturbing the operation
of the control system or any other I/O
module in the system
The locking tab disables the module
before removal for defined handling of
the field objects when removing the
module
© ABB - Page 64
 System 800xA
Control & I/O Adaptability to Change
Open architecture design
Supports global accepted
industrial standards
Easy integration of network
and field communication
protocols
Provides direct
communications with
traditional ABB DCS
controllers
TCP/IP
Ethernet Enhance control strategies
with existing and future
standard-based COTS
Open architecture lowers applications and products
© ABB - Page 65

lifecycle costs
 System 800xA
Control & I/O Cost Effective Maintenance

Self-diagnostics
Performance reporting
LED displays
Operator workplace
Remote messaging (mobile
telephones, pagers and email)*
Automatic submittal of CMMS
work order *
Hot swap maintenance
On-line changes of application
program and configuration

Comprehensive maintenance
© ABB - Page 66

features reduce down-time

* system option
© ABB - Page 67