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TRANSCRIPT
3C2011
, ABB , 2011
3C
( )
Month DD, Year | Slide 2© ABB Group
ABB
–
SIL 3
HART FF )
: CIM/MES, ERP, CMMS
800xA
Month DD, Year | Slide 3© ABB Group
© ABB Group September 5, 2011 | Slide 4
Power DistributionPower Management
Process ElectrificationLV & MV
Ethernet Control Network
Remote Operator andEngineering Clients
System Servers
Process Automation
Engineering
Safety / ESD
Knowledge Portals as Thin ClientsMES and Business Systems
ECS, ISA-95, OPC…
3rd party PLC’s
Serial, OPC.. Operation
LocalPanels
ProcessInstrumentation
- Switchgears- Smart MCC’s- Frequencyconverters- Multi-drive
- Network control & protection- Load Shedding
TCP/IPIEC61850
Extended Operator Workplace
ABB DCS - 800xA System Overview
IMAsset Server
ConnectivityServers
© ABB Group September 5, 2011 | Slide 5© ABB Group September 5, 2011 | Slide 5
Power AutomationProcess Automation
Control Room
Control System
Process Control
Field Network
Plant Network
Control Network
IED
Process ControlWorkplace
System Server
IEC 61850 Network
ElectricalWorkplace
Turbine, Water + Steam Cycle, Unit Control, Boiler, FGP …
Generator Protection, Transformer Protection,MV / HV Switchyard, Excitation, Synchronization
InstrumentationDrives LV Switchgear
IEC 61850Substitute Hardware I/O
MV/HV ProtectionMV/HV Control MV Drives
Substation Automation
800xA Device Management IEC 61850 Integrated Process and Power Automation
© ABB Group September 5, 2011 | Slide 6© ABB Group September 5, 2011 | Slide 6
Integration of 3rd Party Protection RelaysArchitecture Overview
(IEC61850 GOOSE)
AC 800M Controller
Operator Workplace
Client / Server Network
Vertical Integration(IEC61850 MMS)
System servers
Horizontal Integration
Integration of IEC61850 compliant 3rd Party Protection & Control Relays is similar to ABB Protection & Control Relays
Multi-vendor Interoperability
© ABB Group September 5, 2011 | Slide 7© ABB Group September 5, 2011 | Slide 7
Example: Circuit Breaker Faceplate developed by ABB Norway
IEC 61850 in System 800xA
© ABB Group September 5, 2011 | Slide 8© ABB Group September 5, 2011 | Slide 8
LibrariesREUSE library from O&G
O&G in Norway has a complete library including IEC 61850 support named REUSE including preconfigured objects with Faceplates for e.g. Circuit-Breaker, Transformer, Generator, Bus bars
Contact person: oilandgasreuseorderbox/NOABB/ABB@ABB
CCR
FIELD
Redundant Aspect Servers
Red. Connectivity Servers
Redundant Client/Server Network
Power SCADA C/R SCADA MEP SCADA Alarm SCADA Backup Chemil SCADA GAS SCADA WWT SCADA UPW SCADA
Edge Switch
POWER
Redundant
S800 I/O
Core Switch CCR
FIELDRedundant Control Network
C/R
Redundant Redundant Phase 1 Phase 2
MEP
Redundant Redundant Phase 1 Phase 2
OPC to Gas /Chemical / Waters Systems
Fire Walls
n pairs of cables
Coming fromGasChemicalWaters ….
* / by others
By packages
ABB FMCS System Structure for XX Fab Plant
© ABB Group September 5, 2011 | Slide 10
Power DistributionPower Management
Process ElectrificationLV & MV
Ethernet Control Network
Remote Operator andEngineering Clients
System Servers
Process Automation
Engineering
Safety / ESD
Knowledge Portals as Thin ClientsMES and Business Systems
ECS, ISA-95, OPC…
3rd party PLC’s
Serial, OPC.. Operation
LocalPanels
ProcessInstrumentation
- Switchgears- Smart MCC’s- Frequencyconverters- Multi-drive
- Network control & protection- Load Shedding
TCP/IPIEC61850
Extended Operator Workplace
ABB DCS - 800xA System Overview
IMAsset Server
ConnectivityServers
© ABB Group September 5, 2011 | Slide 11
ABB DCS 800xA –
• (data) (information)
(Oracle DB ), CIM/ERP/CMMS )
DCS
Data direct link Office Excel
IE Remote Desktop Access
Calculations and SoftpointsTo transform data into actionable information for timely decision-making and process tuning
PLC + !
© ABB Group September 5, 2011 | Slide 12
ABB Data Direct Excel Add-In ExcelVBA
Information Management : Excel Data Access Reporting
© ABB Group September 5, 2011 | Slide 13
Anti-virus Server
Fiber Optics (Star)
Redundant Client/Server Network (Ethernet)
GAS
XX FMCS
Chemical
ERC
Clean Room HVAC
FMCS
Operator Stations x 4 (Dual screens)
• 2oo3 Redundant Aspect Servers (AS)
• Dual Domain Controller (DC)
• Dual Info. Management Server (IM)
Office Network for Firewall, EDMS, and Info-Center PC
VESDA, PA, FACCTV, Access
EngineeringStation (ES)
Red. CS
LED Ticker
OS x 3OS x 3 OS x 1 OS x 1
Core Switch
Edge Switch
Edge Switch
OS x 2
Controllers & I/Os not shown!
Controllers & I/Os not shown!
Red. CS
Edge Switch
WTS
Red. CS
Controllers & I/Os not shown!
OS x 2Red. CS x 2
Edge Switch
Red. CS
Controllers & I/Os are not in FMCS scope.
Firewall
AO Server File backup Server
Red. CS
To 12D & Office network
OPC(by Others)
UPW/PCW/WWT
Edge Switch
Prof
ibus
-DP
Red. AC800HI Controllers & Safety I/O
PLC-2
PLC-n
PLC-1
Edge Switch
Prof
ibus
-DP
Server
© ABB Group September 5, 2011 | Slide 14
HVAC
Ref: Wang, S., 2008, Supervisory and Optimal Control of Building HVAC Systems: A Review, HVAC&R Research, Vol. 14, No. 1.
ChillerAC800M Controller/Communication Interface
Information Manager
FMCS HMI / 800xA DCS
Operation Supporting System
Engineer
© ABB Group September 5, 2011 | Slide 15
Power DistributionPower Management
Process ElectrificationLV & MV
Ethernet Control Network
Remote Operator andEngineering Clients
System Servers
Process Automation
Engineering
Safety / ESD
Knowledge Portals as Thin ClientsMES and Business Systems
ECS, ISA-95, OPC…
3rd party PLC’s
Serial, OPC.. Operation
LocalPanels
ProcessInstrumentation
- Switchgears- Smart MCC’s- Frequencyconverters- Multi-drive
- Network control & protection- Load Shedding
TCP/IPIEC61850
Extended Operator Workplace
ABB DCS - 800xA System Overview
IMAsset Server
ConnectivityServers
Current Situation
How can productivity be increased significantly?
How can production be optimized on short term schedules?
How can capital requirements and stock inventory be reduced?
How can performance of logistics be improved?
How can formal quality requirements be achieved while cost remain the same?
Automation on shop floor level has mainly been done
Systems on ERP level are installed
Maintenance systems are partly available
Optimization of automation is often done
Data from enterprise management level
devicesUp to 200 parameters per field device / increasing number of field
devices
Data from the field level
Production/Plant Management&
Process Management
Business Integration
The flood of information must be dealt with!
Layer model
Level 0
Level 1
Level 2
Level 3 ProductionManagement Level
PlantControl Level
ProcessControl Level
CPMCollaborative ProductionManagement
ERP
Single Control
EnterpriseManagement LevelLevel 4
CPM (Collaborative Production Management)corresponds to
MES (Manufacturing Execution System) with further
Collaborative support for production
Layer model
PLC (Siemens, Allen-Bradley...) DCS, SCADA…
Executives
Process engineers, Production & Quality Manager
Controller & Production planner
Maintenance & Operating engineers
IndustrialIT cpmPlus tailored data
EfficiencyProcess run always close to the optimum
Effective production and maintenance management
Higher manpower efficiency
Improved stock and inventory control
QualityLower product quality variability
ProductivityLower thermal and electrical energy consumption
Reduced asset downtime and production costs
Increased production under lower costs
Continuous improvementKPI target monitoring for continuous improvement
Higher frequency of timely business decisions
Proof-of-performance and compliance
IndustrialIT cpmPlus targets
Chemicals & PharmaceuticalBASF, Bayer, Sanofi Aventis, Wacker, Brillux, Janssen Pharmaceuticals, DOW, Clariant, EWE, DSM, SKW Piesteritz, Bayer Healthcare, Böhringer Ingelheim…
Pulp & PaperWeyerhaeuser, Stora Enso, UPM, Visy Paper, M-Real, Norske Skog, Mondi, Sappi, SCA, Marchi, CVG Papier, April Asia…
Metall: North American Stainless, Arcelor, Celsa, Thyssen Krupp, Corus, Outokumpu, Avesta Polarit, Sandvik, BaoSteel, China Steel…
Cement & Minerals: Holcim, Lafarge, CRH, Siam Cement, Votorantin, BuzziUnicem, CVRD, Alunorte, Codelco, Boliden, Sherrit International…
Weitere Branchen…OMV, Warsteiner, Gunnar Dafgaard AB Frozen Products, Statoil, Stadtwerke Düsseldorf…
Extraction of References
© ABB Group September 5, 2011 | Slide 22
” ”–
© ABB Group September 5, 2011 | Slide 23
© ABB Group September 5, 2011 | Slide 24
ABB 800xA eDMS (1/6)
© ABB Group September 5, 2011 | Slide 25
”EDMS_HVSS” eDMS
ABB 800xA eDMS (2/6)
© ABB Group September 5, 2011 | Slide 26
eDMSABB 800xA eDMS (3/6)
© ABB Group September 5, 2011 | Slide 27
eDMS Microsoft Office PDFAUTOCAD jpg bmp
ABB 800xA eDMS (4/6)
© ABB Group September 5, 2011 | Slide 28
ABB 800xA eDMS (5/6)
© ABB Group September 5, 2011 | Slide 29
CAD drawingABB 800xA eDMS (6/6)
© ABB Group September 5, 2011 | Slide 30
-
© ABB Group September 5, 2011 | Slide 31
Hardware Overview---Alarm
: I/O (1/5)
© ABB Group September 5, 2011 | Slide 32
CR
Alarm
: I/O (2/5)
© ABB Group September 5, 2011 | Slide 33
IO
IO
: I/O (3/5)
© ABB Group September 5, 2011 | Slide 34
: I/O (4/5)
© ABB Group September 5, 2011 | Slide 35
“Reference”
: I/O (5/5)
© ABB Group September 5, 2011 | Slide 36
: PC, Network & Software Monitoring
Monitoring of your importantIT Assets, for example
SoftwareProper execution, CPU utilization, Resource utilization
Computer hardwareHard disk utilization, Overall resource availability, Network usage
Computer peripheralsPrinters (toner, paper), UPS’s (battery health)
Network devicesSwitches, routers, firewalls
Business equipmentNetworked PBX’s, Copiers, Faxes
Any device that runs Windows or supports SNMP
© ABB Group September 5, 2011 | Slide 37
, Server PC
Link Dell (utility tool)
© ABB Group September 5, 2011 | Slide 38
800xA
© ABB Group September 5, 2011 | Slide 39
Anti-virus Server
Fiber Optics (Star)
Redundant Client/Server Network (Ethernet)
GAS
XX FMCS
Chemical
ERC
Clean Room HVAC
FMCS
Operator Stations x 4 (Dual screens)
• 2oo3 Redundant Aspect Servers (AS)
• Dual Domain Controller (DC)
• Dual Info. Management Server (IM)
Office Network for Firewall, EDMS, and Info-Center PC
VESDA, PA, FACCTV, Access
EngineeringStation (ES)
Red. CS
LED Ticker
OS x 3OS x 3 OS x 1 OS x 1
Core Switch
Edge Switch
Edge Switch
OS x 2
Controllers & I/Os not shown!
Controllers & I/Os not shown!
Red. CS
Edge Switch
WTS
Red. CS
Controllers & I/Os not shown!
OS x 2Red. CS x 2
Edge Switch
Red. CS
Controllers & I/Os are not in FMCS scope.
Firewall
AO Server File backup Server
Red. CS
To 12D & Office network
OPC(by Others)
UPW/PCW/WWT
Edge Switch
Prof
ibus
-DP
Red. AC800HI Controllers & Safety I/O
PLC-2
PLC-n
PLC-1
Edge Switch
Prof
ibus
-DP
© ABB Group September 5, 2011 | Slide 40
XX FMCS 3rd party
AB PLC
SIMENS PLC
VESDA system
WinCC OPC
Intouch OPC
iFix OPC
Kepware OPC
Kepware LinkMaster
© ABB Group September 5, 2011 | Slide 41
Rexchip ( ), TaiwanClient: Rexchip Electronics Corp., TaiwanSite: Hou Li / Taichung, TaiwanApplication: 12” Silicon Fab. for DRAM, 80,000 wafers per month. Total plant control systems incl.
FMCS (Facility Monitoring & Control System)Clean Room & HVACWater TreatmentGas & Chemical SupplyLife Monitoring Systems ( Fire, VESDA, CCTV, Access Control )
System 800xA V4.1 with16 OS distributed in 5 locations2oo3 AS, 8 Red. CS, 2 IM, 2 DC, 1 AO28 Safety Controller (Redundant) w/ 14,000 I/O39 BPCS Controller (Redundant) w/ 28,000 I/O2,000 HART Instrumentation Devices for AOProfibus to Siemens, A-B, Danfoss Inverter…OPC to 3’rd party PLCs, Win-CC, VESDA,… etc.SIL Engineering support3rd party systems integration
EDMS (Electronic Document Management System)SPC (Statistic Process Control)
Start Operation in May 2007