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© ABB Control Technologies September 14, 2012 | Slide 1 Steve Hawkins, Competitive System Replacement Program Manager, NA Third Party System Evolution (TPSE) Overview
© ABB Control Technologies September 14, 2012 | Slide 1
Steve Hawkins, Competitive System Replacement Program Manager, NA
Third Party System Evolution (TPSE) Overview
Third Party System Evolution Presentation Agenda
What is Third Party System Evolution (TPSE)?
What solutions and technology do we have?
Where have we implemented TPSE?
Case Study
What are your requirements?
© ABB Control Technologies September 14, 2012 | Slide 2
System 800xA
Taylor TM MOD300
Master
Harmony
Melody
Third Party System Evolution What is it?
© ABB Control Technologies September 14, 2012 | Slide 3
Start with the technology we use to evolve our own legacy systems to 800xA
System 800xA
Taylor TM MOD300
Master
Harmony
Melody
Third Party System Evolution What is it?
© ABB Control Technologies September 14, 2012 | Slide 4
TPSE is an extension of ABB’s expertise in evolving other systems…So, from an 800xA perspective, it’s just another system
Other products…
Batch Manager
Information Manager
Assets Optimizer
Common base: Aspect Integrator Platform
Field Bus networks
AC800M
Advant MOD300
Harmony Melody
DCI
Third Party Systems
PI, CMMS,…
Brings the power of Integration to Third Party Systems
Dedicated Connectivity on ABB 800xA’s Aspect Integrator Platform
Specific Object types and uploader
Extend 800xA Functionalities to Third Party Systems (Aspects, Trends, Video, Electronic Documentation, …)
Integrated as a standard ABB System
Third Party System Evolution Why Does It Work with System 800xA?
© ABB Control Technologies September 14, 2012 | Slide 5
Aspect Objects provides
Faceplates, Graphic Symbols
Alarm management
Trend, History
Drawings
Instructions
Pictures
Etc….
Documentation
Faceplates
Graphics, Alarms Graphic & Pictures
Aspect Object
© ABB Control Technologies September 14, 2012 | Slide 6
Third Party System Evolution – What it Enables.... Aspect Object Technology
Third Party System Evolution Portfolio
© ABB Control Technologies September 14, 2012 | Slide 7
Honeywell
TDC 2000/TDC3000
Experion
Emerson
RS3
Provox
DeltaV
Siemens
Teleperm M
WinCC
PCS7
Invensys
Foxboro I/A
Emerson Provox – France; Arkema (Chem), HMI replacement
Emerson RS3 – Ireland; Janssen (Pharma), Rip and Replace
Emerson RS3 – UK; Victrex (Chem), Rip and Replace
Emerson RS3 – Sweden; PA Resins (Chem), Rip and Replace
Honeywell TDC3000 – Norway; Norske Skog, Rip and Replace
Honeywell TDC3000 – France; Arkema (Chem), HMI replacement
Siemens S5 - Norway; Norske Skog, Rip and Replace plus termination cabling
Siemens Teleperm M – France; HMI replacement
Siemens Teleperm M – Netherlands; HMI replacement
Siemens Teleperm M – Denmark; HMI replacement
Third Party System Evolution Installations and References
© ABB Control Technologies September 14, 2012 | Slide 8
© ABB Control Technologies September 14, 2012 | Slide 9
Phase 1 – HMI
Connectivity – OPC DA, A&E
Create object types
Graphic and Faceplate conversion
Phase 2 – Integration enabled due to System 800xA
Historian
MES/ERP
Field Buses – Drives, IEDs, Analytics, ….
Phase 3 – Controllers and I/O
Cable solutions – leaving field terminations in place
Application code translation
Third Party System Evolution A Stepwise Approach - No Need to “Rip and Replace”
© ABB FR - 762 ORG M379 rev 00 September 14, 2012 | Slide 10 ABB confidential
System Audit
Life Cycle
Impacts analysis
Customized
Evolution Plan
Evolution
To 800xA
Focus on your current reliability problem
Use installed equipment as much as possible
Find the best Evolution Plan
Stepwise or Rip and Replace?
How long in each step?
Collaborative Approach
Third Party System Evolution Implement the Right Solution for Your Problem
Similar look as ABB Controllers
Alarm list
Event list
Trend
Object Display
© ABB Control Technologies September 14, 2012 | Slide 11
Third Party System Evolution Solutions: Typical Faceplate look for Honeywell TDC Connect
Base Object Type Library already exists for Honeywell TDC Connect REGAM
PID
RATIOCTL
DIOUTNIM
REGPVNIM
HGPIDNORM
DIGINHG
And more…
53 Honeywell Object types supported today © ABB Control Technologies September 14, 2012 | Slide 12
Third Party System Evolution Solutions: Examples of supported types for TDC Connect
© ABB Control Technologies September 14, 2012 | Slide 13
Third Party System Evolution Solutions: Typical Graphic Evolution for TDC Connect
© ABB Inc. September 14, 2012 | Slide 14
Site condition pre-project Obsolete Provox HMI (Provue consoles) Difficulties and high cost to repair Provox Keyboard 3 type of controllers obsolete soon (MUX, PCIU and DCU) 1 type of controller active for many years (UOC)
Request from the customer
Provide an alternative migration solution to Emerson and replace only what is necessary
Case Study: Arkema St Auban Third Party System Evolution
© ABB Inc. September 14, 2012 | Slide 15
Arkema St Auban case study System architecture at the beginning of the project
ST5
@2-22@2-21@2-20
ST2
MODEM
@2-18 @2-19
TAP
fibre optique
trunck cable 120 m 1 2 3 4
5 6 7 8
BUS MSP SECONDAIRE TECHNOLOGIE HII
1
UOC26SRX
K32653266/3267
PANELSEIS
@1-8
UOC35SRX
LIQUE COPOCOMMUNS
PANELSEIS
@1-9
UOC34SRX
COMESSASILOS
PANELSEIS
@1-14
UOC33SRX
K7203STRIPPING
HOMO
PANELSEIS
@1-13
UOC32SRX
K7102LIQUEHOMO
PANELSEIS
@1-12
UOC31SRX
K5201DEMONO
PANELSEIS
@1-11
UOC30SRXMAT.
PREM.
PANELSEIS
@1-30
UOC27SRX
K32753276/3277
PANELSEIS
@1-7
DCUPCIUPCIU1ST1
MUXMUX1ST1
PB600EDM
@3-3@3-5@3-4
ST3ST2ST1
HDL@0-2
CHIPDEC2SERVEUR
PIHUB
HDL@0-3
VAXALPHAENVOX
Configurateur
PANELSEIS
UOC41SRX
LV6
@1-29
CONS1CALC1VME@0-4
Postes de conduite SUSP Postes de conduite MSP
Historique
BRIDGEBUS 2
MODEM
CONS2CALC2VME@0-5
TAP
1234
5
76
8
Réseau ST0
RESEAU ST0 HIISECONDAIRE
Bus 0
Réseau SUSPENSION
Bus 3
RESEAU PVC
Rev 6 LTD 3SEC
BUS 3
TAP1 2
TAP1 2
E/SMUX/DM15 bacs
UOC9SRXLiqué
Hamon 2b
@2-29
EISMUX/DM11 bacs
UOC8SRX
Mat 1ère
@2-28
EISMUX/DM14 bacs
@2-25
EISMUX/DM14 bacs
UOC6240SRX
K6240
@2-24
EISMUX/DM11 bacs
UOC6230SRX
K6230
@2-23
TAP
ArmoirePANELS
UOC7SRX
Rejets aqeux
@2-27
1234
5
76
8
BAC E/SRejets
Réseau MSPBus 2
MUX1MSP MUX
@3-15
ST2
UOC6250SRX
K6250
EISMUX/DM12 bacs
UOC2220SRX
K2220
EISMUX/DM12 bacs
UOC2210SRX
K2210
EISMUX/DM13 bacs
UOC0SRX
Mat 1ère
ArmoirePANELS
UOC12STRIP I ET 2
ArmoirePANELS
UOC13STRIP 3
BAC E/Sstripp 1
BAC E/Sstripp 3
BAC E/Sstripp 2
AUT2003NIRO 1/2
IDI
PB400
AUT2002NIRO 3
IDI
AlarmesH.S
PB400
PB200
BAC E/Sstripp 3
liaison RS485 Automate/IDI
1 PANEL par carte E/S
BAC E/SEmulsif
ArmoirePANELS
Bus 3
BRIDGEBUS 1
trunck cable
TAP1 2MODEM
MODEM TAP BUS COPO SECONDAIRE TECHNOLOGIE HII
DI: 20DO:12 AI: 40PCI: 4
DIO: 264
Points: 31dans
4:IAC 2cartes2: Configurable
DI: 48DO: 48
Pts console:5500 pts
W:\F
RP
A\S
TAU
\$D
ATA
\GR
P-G
RO
UP
S\S
mm
ciiia
\UN
ITE
S\P
VC
: AR
CH
.PR
OJE
T R
esea
ux S
T0 e
t MS
P B
US
SE
C re
v6.v
sd
2 Provue consoles
About 5000 IOs
4 types of controllers
Batch applications: 5 autoclaves
© ABB Inc. September 14, 2012 | Slide 16
Arkema St Auban case study ABB proposed solution
Method: step – wise evolution Replacement first of Provue consoles by ABB 800xA interface Implementation of ABB 800xA Batch Manager Replacement of MUX, DCU and PCIU controllers when necessary Replacement of UOC controllers when necessary
Tools: ABB PSM Connect
Dedicated Emerson Provox object types Dedicated uploader
© ABB Inc. September 14, 2012 | Slide 17
Arkema St Auban case study First step: HMI and Batch applications migration
Customer data collection (Graphic display, DSR, Templates,…)
Develop typical graphic elements
Database loading in ABB
Graphic displays development
Operator interface development
Batch procedure development
FAT / SAT
© ABB Inc. September 14, 2012 | Slide 18
Arkema St Auban case study Implementation in Phases ABB 800xA on top of Provox in production since September 2010 for std operation and since June 2011 for
all Batch applications
Phase 1: both system in parallel, with ABB in read only during 1 month
Phase 2: both system in parallel, with operation on ABB for std operation
Phase 3: Only ABB for Batch applications
Architecture during the HMI evolution
© ABB Inc. September 14, 2012 | Slide 19
Arkema St Auban case study Implementation in Phases and What’s Next
HMI phase 4 Stop and disconnect Provue consoles
Next phase
Begin Provox controller and IO replacement
© ABB Group September 14, 2012 | Slide 20
