T314-02 System Architecture - RevE

8/19/2019 T314-02 System Architecture - RevE

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System 800xA Training

Chapter 2 - 1

Chapter 2 System 800xA Architecture

TABLE OF CONTENTS

Chapter 2 System 800xA Architecture .................................................................................................................................... 1 2.1 General Information...................................................................................................................................................... 2

2.1.1 Objectives .............................................................................................................................................................. 2 2.1.2 Legend................................................................................................................................................................... 2 2.1.3 Reference Documentation ...................................................................................................................................... 2

2.2 System Overview.......................................................................................................................................................... 3 2.2.1 The Power of Integration........................................................................................................................................ 4 2.2.2 Options Grouped in Functional Areas..................................................................................................................... 5 2.2.3 Controller Integration ............................................................................................................................................. 6 2.2.4 Use of Standards .................................................................................................................................................... 6 2.3 Aspect Objects Concept ................................................................................................................................................ 7 2.3.1 Aspects and Objects ............................................................................................................................................... 7 2.3.2 Example of a Control Valve ................................................................................................................................... 8 2.3.3 Intuitive Navigation ............................................................................................................................................... 9 2.3.4 Aspect Framework ............................................................................................................................................... 10

2.4 System Topology........................................................................................................................................................ 11 2.4.1 Domain Server..................................................................................................................................................... 12 2.4.2 Aspect Server....................................................................................................................................................... 12 2.4.3 Connectivity Server.............................................................................................................................................. 12 2.4.4 Application Server ............................................................................................................................................... 12 2.4.5 Plant Network...................................................................................................................................................... 13 2.4.6 Client/Server Network.......................................................................................................................................... 13 2.4.7 Control Network .................................................................................................................................................. 13 2.4.8 Single Node System ............................................................................................................................................. 14 2.4.9 Large System ....................................................................................................................................................... 15 2.4.10 Remote (Thin) Client.......................................................................................................................................... 16 2.4.11 Virtualization of Server Nodes............................................................................................................................ 17 2.4.12 AC 800M Redundancy ....................................................................................................................................... 18 2.4.13 System On-line Upgrade .................................................................................................................................... 18

2.5 Client / Server Principle.............................................................................................................................................. 19 2.5.1 Aspect Directory.................................................................................................................................................. 19 2.5.2 Example: Graphic Display.................................................................................................................................... 19 2.5.3 Distributed Engineering........................................................................................................................................ 20 2.5.4 Multi-System Integration...................................................................................................................................... 21

2.6 Configuration Utilities ................................................................................................................................................ 22 2.6.1 Configuration Wizard........................................................................................................................................... 22 2.6.2 System Configuration Console ............................................................................................................................. 24


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T314-02 System Architecture - RevE

Chapter 2 - 2

2.1 General Information

2.1.1 Objectives

On completion of this chapter you will be able to:

Tell how 800xA fits into the IIT strategy

Describe the network structure in an 800xA architecture

Describe the functionality of the major components

Explain the concept of Aspects and Objects

Explain the Client/Server principles

2.1.2 Legend

> Indicates when you go from one menu to a sub-menu

Italic Indicates object and file names

“ “ Indicates dialog box buttons, tabs, menus etc.

Bold Indicates important topics

Indicates start/explanation of student activity

2.1.3 Reference Documentation

3BSE038018 System 800xASystem Guide – Functional Description

3BSE041434 System 800xASystem Guide – Technical Data and Configuration

3BSE034463 System 800xA Network Configuration

2PAA101888 System 800xATools


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Chapter 2 - 3

2.2 System Overview

The Industrial IT Extended Automation System 800xA is a comprehensive processautomation system. It covers operation and configuration of continuous and batchcontrol applications.

System 800xA has been developed incorporating Information Technology with theexperience and know-how collected over decades of successful deliveries andcustomer installations.

800xA System offers more than a traditional Distributed Control System. It gives youa single application to organize and access all plant information.

As expected, you have functionality like graphics, faceplates, alarm management and

trending available. However, with the unique integration principles based on theAspect Object technology, you can easily integrate information like Live Video,Documentation (using Word for example), Quality Analysis, and MaintenanceInformation (from SAP or Maximo for example).

System 800xA provides a secure, reliable, control environment with built in securityfeatures such as access control, user authentication, and audit trail capability.


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2.2.1 The Power of Integration

In order to be competitive, various plant entities, departments, and personnel have towork as one flexible, integrated, collaborative environment.

Integration of systems, applications, and devices creates a powerful informationarchitecture where all information is available for use in the system and can be

provided to the plant personnel. Imagine a system where with one click an operatorcould access any information required to make an informed decision regardless ofwhere it resides, or a maintenance technician could access device commissioningdisplays, documentation, current health status, and a list of active work orders.

System 800xA Extended Automation is an integration platform with connectivity toenterprise and plant systems, applications, and devices that improves operations,engineering, control, and maintenance. It also provides a collaborative environment

where real time decision making is a reality.


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Chapter 2 - 5

2.2.2 Options Grouped in Funct ional Areas

The 800xA system functionality is divided into a Base System and a set of options,grouped in Functional Areas. The options represent functions that can be added to thesystem based on the needs of the process that should be controlled.

OperationsProvides a consistent method for accessing enterprise-wide data and for interactingwith multiple applications from any connected workstation in the plant or office.

EngineeringIntegrated engineering environment supports the complete lifecycle of the automation

project, from planning, through configuration and library management, tocommissioning and operation to minimize system ownership costs.

SafetyScalable IEC 61508 and IEC 61511 compliant SIS (Safety Instrumentation System)that spans the entire safety loop, including SIL rated field devices, I/O modules,controllers, and field actuators.

Information ManagementCollects, stores, retrieves and presents historical, process and business data to enhancethe usefulness of data from all operations.

Batch ManagementRecipe management, batch and procedural control according ISA S88.01

Asset OptimizationAssess and reports equipment conditions in real-time to optimize maintenance andcalibration work flows.

Control and I/OSuite of standards-based hardware and software, complimented with a full line ofindustrial I/O interfaces.

Field Buses / Device Management

Integration of intelligent field devices via all major fieldbus standards.


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2.2.3 Controller Integration

Controllers are integrated with the system through “Connectivity packages”, which areoffered as options to the 800xA System. These packages provide access to real timedata, historical data, and alarm & event data for instance using predefined faceplates.

Any of the traditional ABB control systems can be evolved using System 800xA. Inaddition, connectivity packages and services exist to bring 3rd party PLC’s and DCSsystems into an 800xA environment.

Simultaneous Connectivity

AC 800M (default)

Advant Master AC400 & AC100

Symphony Harmony Infi-90

Symphony Melody / AC 870P

Freelance / AC 800F

DCI System Six Advant MOD 300

Safeguard 400

Honeywell TDC3000 (HSM)

Emerson PROVOX (PSM)

PLC Connect (via OPC Server)

Controller Integration

Predefined faceplates

Link to Controller database

Access to real time and historical data

2.2.4 Use of Standards

System 800xA uses standard hardware, operating system software and protocols. Thisallows data to be obtained not only from ABB systems but from a variety of sourcessuch as other brands of control systems or from lab entries.

It also allows making this data available to ABB and other manufacturers’ systemssuch as historians and maintenance management programs.

Microsoft Windows 7 / Server 2008

Internet Explorer

ActiveX Controls

OPC - OLE for Process Control

Microsoft Component Object Model(COM)

PROFIBUS

FOUNDATION Field bus

HART

Windows Presentation Foundation(WPF)

IEC61850 (Electrical integration)

IEC61508 (Functional Safety)

etc.


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2.3 Aspect Objects Concept

A central problem in plant operations, as well as asset life cycle management, is theneed to organize, manage, and have access to information for all different aspects of agreat number of plant and process entities.

The Aspect Objects TM architecture is a cornerstone of the Industrial IT concept andenables enterprise wide information availability in a unified way. It providesinformation-centric navigation – a consistent way to instantly access all informationwithout having to know how and by which application the information is handled.

2.3.1 Aspects and Objects

The system model objects of the real process equipment or entities are called Aspect

Objects . They can be physical process equipment, like a valve, or more complex, likea reactor. Other examples are: products, material, batch procedures, manufacturingorders, and customer accounts.

Each of these Aspect Objects is a container of references to all information pertainingto a real object. The various types of information related to the object are calledAspects . Examples are: process graphic, faceplate, alarm, trend, report, orderdefinition, mechanical layout etc.

ModelObject

RealObjectReal

Object

Applications

ControlBuilder M

ProcessPortal

MS Excel

Auto CA D

Aspect Systems Aspects

Control

Faceplate

Graphics

Report

Drawings

It is necessary to be able to implement these aspects using many different applications, both existing and new, from ABB, third parties and customers. These applications arecalled Aspect Systems and must cooperate to provide an integrated view andfunctionality of the object.

Examples are: Graphics Builder for graphics, Auto CAD for mechanical layout, SAPfor order handling etc.


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2.3.2 Example of a Contr ol Valve

For example a valve is a real object and has many types of data associated with it. Ithas manufacturer’s specifications, mechanical drawings, a maintenance schedule andhistory, ordering information for parts, physical location in the plant, faceplate foroperator interface, graphic symbol for display on graphics, and many other possibletypes of information.

Maintenance RecordMaintenance Record

Operator NotesOperator Notes

P & I DiagramP & I Diagram

Product DescriptionProduct Description

Simulation ModelSimulation Model

Control LogicControl Logic

Control DialogControl DialogControl Dialog

Process GraphicsProcess GraphicsProcess Graphics

Traditionally, these types of information are found in many separate systems or inmany different document formats. An Aspect Object presents this data as a menu ofchoices accessible by right clicking on the object anywhere it appears in the system.The various types of information related to the object, in this case the valve, are calledAspects .


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2.3.3 Intuitive Navigation

Quick access to displays and information is provided with web browser tools.Favorites, history lists, shortcuts, and hot keys provide navigation through a process

production facility quickly and accurately.

Right click on theobject in t he Graphic

Avai labl e Asp ects

Right click on the objectin the Alarm List

Use of the right mouse button provides access to additional details via a context menu.The same context menu is available, showing all aspects, independent whether youselect it e.g. in the graphic display or in the alarm list.


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2.3.4 Aspect Framework

From a software architecture perspective, the foundation of the 800xA System is theAspect Framework (afw). It is a software package that integrates all Industrial IT enabled products via their Aspect Objects, irrespective of where they may reside in thenetwork.

Although the various aspects and their associated software may reside on multiplenetworks or computers, each Aspect Object carries with it the built-in collection ofcharacteristics or Aspects . All aspect objects are stored in a central location called theAspect Server.

NOTE! The Aspect Framework can handle up to 200.000 AspectObjects.

Although all objects reside in this central location, data needs to be configured onlyonce for use throughout the system. There are many Aspect Systems and thus many

options for where data can be entered. There are also many places where the same datacan be viewed so that generally, data can be entered and viewed where it is relevant.


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2.4 System Topology

The System 800xA architecture assumes a system of computers and devices thatcommunicate with each other over different types of communication networks, asillustrated conceptually here.

The Workplaces uses either dedicated client computers or combined client/servermachines allowing both client and server applications to run in one PC for largerconfiguration.

Fieldbus

Client/server Netwo rk #1


Control Network #1

Control Network #2

Field Devices

DomainServer(s)

Controllers

ConnectivityServer(s)

AspectServer(s)

Appl icationServer(s)

Workplaces

Single1oo22oo3

Single1oo2

System communication in the 800xA System is based on Ethernet and TCP/IPnetworks. Servers run software that provides system functionality, Workplaces runsoftware that provides various forms of user interaction.

NOTE! Server configuration and selection are important factorsfor system performance.

The 800xA system uses a central licensing mechanism. One designated computer,typically the domain controller, should contain the central licensing server (CLS).


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2.4.1 Domain Server

Small systems can run without a Domain Controller. In this case the nodes and usersare handled by a Windows Workgroup. The configuration of users and security mustthen be done on all nodes separately within the Workgroup.

The user handling in a Windows Domain is done from a central location – the DomainServer. Every domain must have at least one domain server, but for resilience adomain should have multiple domain servers.

2.4.2 Aspect Server

The Aspect Server provides the Aspect Directory and the services related to objectmanagement, names, security, etc. It is the heart of the 800xA system. As such it must

be accessible to all nodes all of the time.In small system systems the Aspect Server can be combined with other functions suchas Application or Connectivity Servers in a single node (computer).

The Aspect Server supports “1 out of 2” or “2 out of 3” redundancy. In “1 out of 2”redundancy, the Aspect Directory is readable and writable as long as one AspectServer is on-line. With “2 out of 3” redundancy, two Aspect Servers must be runningto write to the Aspect Directory, but with any one Aspect Server on-line, the system isuseable for operation but not for configuration (Aspect Directory in read only mode).

2.4.3 Connectivity ServerThe Connectivity Server provides access to the controllers and other data sourcesthroughout the network. Several groups of Connectivity Servers may exist in a system,each serving one set of data sources. The AC 800M Connectivity Server is one ofmany different types of Connectivity Servers in the 800xA System.

Examples of services are:

OPC Data Access

OPC Alarm and Event

System messages

NOTE! Maximum 24 AC 800M controllers (single or redundant)can be connected to one Connectivity Server (single orredundant).

2.4.4 Application Server

Run various types of system applications, such as:

Batch Management

Asset Optimization

Information Management


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2.4.5 Plant Network

The Plant network can be dedicated for process automation purposes or be a part ofthe plant intranet already available on a site.

Further connection of the Plant network to the Internet or any other type of externalnetwork should be performed in accordance with adequate network security practices.

2.4.6 Client/Server Network

The Client/Server network is used for communication between servers, and betweenclient workplaces and servers.

Via a router, the Client/Server network can be connected to a plant intranet, and via afirewall to the Internet. For performance and integrity reasons, connection of foreignsystems directly to the Control and Client/Server networks should be avoided. TheClient/Server network can optionally be made redundant.

For any installation larger than a Single Node system and small systems that useWindows Workgroup, the 800xA system nodes must reside within a dedicatedWindows 2008 Domain. This requires you to set up a domain controller and DNSserver. All other 800xA System server and client nodes must be configured to bemembers of the domain.

2.4.7 Control Network

The Control network is a local area network (LAN) optimized for high performanceand reliable communication, with predictable response times in real time. It is used toconnect controllers to the servers. Controllers are nodes that run control software.

Controllers and Connectivity Servers are connected to the Control network. TheControl network can optionally be made redundant.

Field buses are used to interconnect field devices, such as I/O modules, smart sensorsand actuators, variable speed drives, PLCs, or small single loop devices, and toconnect these devices to the system, either via a controller or directly to a server.

NOTE! For smaller systems and for systems where networkseparation is not desired, the Client/Server Network andControl Network can be combined in one AutomationSystem Network.


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2.4.8 Single Node System

A Single Node System is intended for very small applications, where all 800xA serverand workplace functionalities reside in a single PC.

Fieldbus

combinedClient/server+Control network #1

combinedClient/server+Contro l n etwork #2

Field Devices

Asp ect Server Connectivity Server Workplace(Client)

Controllers

The system has only one node, within which all servers as well as the clientapplications are installed. Only a few controllers can be connected.


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2.4.9 Large System

If the total number of nodes on the Control Network exceeds 50 it is recommended tosplit the Control Network on two or more Network Areas.

Fieldbus

Client/server Network #1


Control Network #1

Control Netwo rk #2

Field Devices

DomainServer(s)

Controllers


Asp ec tServer(s)

Ap pl ic at io nServer(s)

Workplaces

Fieldbus


Controllers

Field Devices


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2.4.10 Remote (Thin) Client

Remote Clients enables remote access to an 800xA system from a standard PC withoutABB-specific software installed. Only the Internet Explorer is required to access thedata.

The Remote Client provides operation capabilities and access to historicalinformation. Configuration capabilities are limited on the remote client.

Internet

Fieldbus

Plant Network #1

Control Network #1

Control Network #2




Asp ectServer(s)

Ap pl icatio nServer(s)

Workplaces

Thin Clients

Field Devices

Thin Clients

Router Firewall

Controllers

Firewall

The remote client functionality is achieved using Windows Terminal Services in anapplication server node. This node is sometimes called the Remote Client Server node.


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2.4.11 Virtualization of Server Nodes

Virtualization based on VMware ESX can be used in 800xA systems to combinemultiple 800xA server nodes onto a single computer. The total number of physicalcomputers required in an installation is reduced significantly.

Asp ectServer

Controller Connectivity

Server

Control network

Client/Server network

Firewall

FieldbusConnectivity

Server

Servers running in thevirtual environment


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2.4.12 AC 800M Redundanc y

System 800xA provides the highest degree of fault tolerance to meet the mostdemanding application needs for maximum system uptime. Optionally redundant I/O,controllers, control networks, FieldBus networks, Connectivity Servers, AspectServers, and Operator Workplaces are available with automatic switchover.

Redundant ModuleBusSolution

Upper CPU Lower CPU

ProfiBus DP

ProfiBusDP-V1 ModuleBus

Optic Cable

CEX-BusCEX-Bus

RCU Link

Redundant I/O Module

Connectivity Server(s)Connectivity Server(s)Control Network #1

Control Network #2

2.4.13 System On-lin e Upgrade

System 800xA SV5.1 supports upgrading a running system without interrupting the production. On-line upgrade is supported for 800xA 5.0 installations and onwards.

General workflow

1. Decouple redundant nodes (start with AS,CS, a client)Or use new hardware if it will be exchanged

2. Upgrade the decoupled nodes

3. Build parallel system with upgraded nodes

4. Gradually move over nodes (clients, remaining servers)Upgrade remaining nodes before connecting to the upgraded system

5. Enable redundant mode


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2.5 Client / Server Princ ipl e

2.5.1 Aspect Directory

The Aspect Framework includes an Aspect Directory , where all aspect objects andtheir aspects are registered, and also all aspect systems and the operations theysupport.

ReportsControl

2 3 4 5

etc. AspectFramework

Aspect

Directory

Client Application 1

Aspect Systems

ProcessGraphics

Reports etc.

To perform an operation on an aspect object, an application (i.e. an Aspect System)retrieves an interface for that operation from the framework.

2.5.2 Example: Graphic Display

Let’s take a process graphic as an example. The aspect “Graphic display” is installedon the Aspect Server and will be called by the Operator Workplace.

Control Network #1

R e a l

- t i m

e d a

t aC o n f i g u r a t i o n d a t a

Operator Workplace(s)


Asp ectServer(s)


Graphic Display

Aspect System

Aspect

Directory

If we look then on a valve within the process display, the icon is provided by theAspect Server and the dynamic status indication (open/closed) is provided by the

Connectivity Server.


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2.5.3 Distributed Engineering

The 800xA System supports distributed engineering:

Off-Site EngineeringIn an off-site environment, engineering tasks may be performed off-line in an isolatedmanner from other users. When the off-site tasks are completed, the usermodifications can be applied to the on-line system through the export/import features.

On- Site Engineering

The on-site Engineering Environment is used for final testing of applications beforeintroducing them into the Production Environment, and for changes and additionsoccurring once the Production System is in operation.

DataExchange

Production Environment

Engineering Environment

DataExchange


DataExchange


Engineering Environment

The import/export feature allows for selective transfer of configuration data betweensystems. In addition, it is possible to compare configuration data between the differentsystems and create reports on the differences.


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2.5.4 Multi-System Integration

System 800xA SV5.1 supports multiple 800xA Systems. Multi-System integrationmakes it possible to view and operate objects configured in one 800xA System(provider) from another 800xA System (subscriber).

Geographically separate 800xA systems with local control rooms to be controlledfrom a common control room

Sectioning of multiple line processes to increase integrity and simplifymaintenance

Making staged commissioning without interfering with running processes possible

System ASystem A System BSystem B System CSystem C

System DSystem D

Provider

Subscriber

Provider Provider

1…10

CentralControl Room

LocalControl Rooms

NOTE! All engineering is done locally at the Provider system;the Subscriber system is for operation only.

NOTE! Not all OCS Connectivities can be used in a Multi-System. For further information refer to System GuideTechnical Data and Configuration(3BSE041434)


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2.6 Configuration Utiliti es

2.6.1 Configuration Wizard

The Configuration Wizard is the central place to:

Create/Delete an 800xA System

Start/Stop an 800xA System

Add extensions to the 800xA System

Connect/Disconnect clients and servers

2.6.1.1 Example of how to Connect/Disconnect Clients

Clients as well as servers can be connected /disconnected from the Aspect Server only.To connect a client, follow these steps:

1. Double click on the icon “Configuration Wizard” on the desktop.

2. Select “System Administration” and click “Next”

3. Select your system and click “Next”.


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4. Select “Nodes” and click “Next”.

5. From the next menu you can add/remove clients and servers.

NOTE! Refer to the separate course T305 “Administration andInstallation” for more information.


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2.6.2 System Configuration Console

The System Configuration Console is a dashboard that provides a single entry pointfor the global configuration settings of an 800xA system, such as:

Appearance and personalization

Client and server load balancing

Maintenance configurations

Security configurations

User administration

To start the System Configuration Console, select “ Start > All Programs > ABBIndustrial IT 800xA > System > System Configuration Console” .

Exercise 2.1

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T314-02 System Architecture - RevE

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