phil coulton, business development manager, mod 300 mod ... · mod 300 evolution update user group...
TRANSCRIPT
© ABB Group April 10, 2014 | Slide 1
MOD 300 Evolution Update User Group Houston 2014
Phil Coulton, Business Development Manager, MOD 300
Phil Coulton ABB Atlanta
MOD 300 Evolution Business Driver
40 years experience
Nuclear Industry UK
Oil & Gas Middle East 15 years
Engineering & Operations
© ABB Group April 10, 2014 | Slide 2
MOD 300 Installed Base Sites 163 sites on July 24, 2013
© ABB Group April 10, 2014 | Slide 3
© ABB Group April 10, 2014 | Slide 4
Investment Protection ABB’s control systems are designed for continuous evolution. It is ABB’s goal to protect our customers’ intellectual investment (i.e. application software) beyond the lifecycles of the underlying platform products (i.e. hardware and software). ABB will not "Remove from Active Sale" any product or "family" of products until an equivalent replacement to those products is available. Once a product has been removed from active sale, ABB will continue to support the product for at least 10 years, although exceptions to this may occur if components or technologies needed are no longer available to ABB. Within this support period ABB will announce a “Last Buy” opportunity at least 12 months prior to the end of manufacturing (except in cases where there is a direct form, fit and function replacement). It is ABB’s intention to provide support for as long as there are significant customer needs after the "Manufacturing End" through field service, repair and by making replacement spares (new or refurbished modules) available.
Limited Classic Active Obsolete
Industry Leader in Lifecycle Management and Investment Protection
Your ABB automation system is designed for continuous evolution Always a path forward
Maximum investment protection
Underlying products are sustained by defined lifecycle phases Active until functional equivalent
Then, minimum 10 years support thru Classic and Limited phases
Documented Lifecycle Status
Manage system lifecycle costs through: Software Asset Management
Evolution Planning
© ABB Group April 10, 2014 | Slide 5
Active
Product Life Cycle
Active (actively sold) until: Removal from Active Sales for new installations
Classic (manufactured and maintained) Last Buy until: Manufacturing End
Limited (serviced) Obsolete (normal support unavailable)
• AC460 Controller • S800 IO • CCF • TCL • TLL
Advant Station Software Released for Sale
Advant Station Hardware
X years Y years Limited Obsolete Classic
> 10 years
High Density I/O
MOD 300/Advant MOD 300/ PPB /800xA Continuous, upward, compatible improvements
HMI
Control
Engineering
1992+ 2001+ 1984+
Evolution through Enhancement
MOD 300 Multibus Console
AdvaCommand
MOD 300 Configurator
AdvaBuild (UNIX)
AdvaBuild (Windows)
Model A/B /SC Controllers
SC Controllers/ AC460
AC460
2005+
800xA CB, CDE, AdvaBuild 3.7
AC800M / AC460
800xA Operations, 800xA for MOD 300
PPB (Operate IT B)
Batch Produce IT 800xA Batch Management TCL Batch Batch 300
MOD 300 Advant OCS for MOD 300
Process Portals and MOD 300
Generation
Area
Tools Product Family Remarks
800xA Engineering The active version is 5.1 Rev A and FP1
•System and Graphic configuration
•Safety and Fieldbus applications
•MOD 300 CCF Library for AC 800M
AdvaBuild 3.7 The active software version is 3.7
AdvaBuild for Unix
Recommend evolution to AdvaBuild 3.6 (Window Server 2008)
Active
Classic
Limited
Obsolete
Product lifecycle status Engineering tools
Class: Consoles
Product Family Remarks
800xA Process Portal
800xA Operations is the eXtended Automation Operator Workplace for 800xA for MOD 300.
Process Portal B
Entered “classic” product lifecycle phase in Dec. 2008. Recommend evolution to 800xA Operations for Process Automation applications.
AdvaCommand
Advant Unix
Hardware Limited (2001) and Software Limited(2011)
Multibus Consoles .
Active
Classic
Limited
Obsolete
Product lifecycle status Operator consoles
Controller Product Family
Remarks
AC 800M Redundant PM861, PM864, PM866, PM891 Safety: PM865 PROFINET, FF, Device NET, Ethernet IP, IEC61850 Goose, …
CI862 TRIO interface
AC 460 TRIO, S100, and S800 MVI available, plus PLC’s
SC Controller Hardware is Obsolete. Software is Limited
Model B Controller
.
Active
Classic
Limited
Obsolete
Product lifecycle status Controllers
I/O Product Family Remarks
S800 I/O S800 I/O is configured using AdvaBuild and Control Builder
S100 I/O S100 I/O configured using AdvaBuild
MOD 300 Taylor Remote I/O (TRIO)
“Blocks” via ABB transitioned to “limited” in 2000. Genus 1 Blocks still Active from G-E.
TRIO on AC460 is ACTIVE. Recommend evolution to S800 I/O.
TRIO on AC800M is ACTIVE
Direct I/O Recommend evolution to the latest members of S800 I/O
High Density I/O Recommend evolution to the latest members of S800 I/O
Active
Classic
Limited
Obsolete
Product lifecycle status I/O subsystem
Communications Product Family
Remarks
eDCN Active. “DCN over Ethernet”
DCN Active. MOD 300 Distributed Communication Network, Token Ring protocol
Advant AC410 D/D, E/E, E/D
Active as Communications Gateway (D/D, E/E, and E/D)
Real Time Accelerator (External)
PU41x
(External RTA)
PU410 for eDCN
PU412 for DCN
Internal (PCI) RTAB
PU514A for eDCN
PU515A for DCN
Active
Classic
Limited
Obsolete
Product lifecycle status Control Networks/Communication Devices
eDCN
DCN
Product lifecycle status Production Management (Batch)
Class: Consoles
Product Family
Remarks
800xA Batch Management
800xA Batch Management is in the “active” phase of its product lifecycle.
ProduceIT Batch
Transitioned to “Classic” in December 2008. Recommend evolution to 800xA Batch Management.
Batch 300 Recommend evolution to 800xA Batch Management.
Active
Classic
Limited
Obsolete
Product lifecycle status Information Management (History)
Class: Consoles
Product Family Remarks
800xA Information Manager
IM is in the “active” phase of its product lifecycle. Can inter-operate with AdvaInform V2 & V3 (consolidation node).
AdvaInform V3 Enterprise Historian
Transitioned to “Classic” in April 2008. Recommend evolution to 800xA IM. Process Portal B
AdvaInform V2 – (UNIX)
Transitioned to “Classic” in May 2005. Recommend evolution to 800xA IM.
History (Multibus) Transitioned to “Limited” in April 2001. Recommend evolution to 800xA IM.
Active
Classic
Limited
Obsolete
MOD 300 Controller: AC460
High Performance
Faster CPU
More user memory
Increased Security
1:1 redundancy
Redundant I/O options
Uses Existing Control Configurations
S800 I/O
S100 (redundant)
TRIO
Open Architecture
PLC and third-party interfaces
Profibus
DCN or eDCN connection
Investigation underway for potential development of new control modules with higher performance and more memory.
Increased value for customers
Long term sustainability
AC460 I/O
S800 Remote I/O
Small Footprint
Wide Range of I/O Modules Types, Including Intrinsically Safe
Redundant Communications
S100 Redundant I/O
Redundancy to the I/O: analog and digital
Supports: Extended Over range (EOVR), Output Hold (OH), and Warm start (Warm)
Re-engineered for long term manufacturability Surface Mount Technology for
Higher Reliability and Extended Life-cycle
© ABB Group April 10, 2014 | Slide 15
Rich Functionality
Long term sustainability
TRIO
Controller interface modules are Active
AC460 MVI
AC800M CEX
ABB commits to support TRIO as long as the GE maintains Form, Fit and Function
GE continues to manufacture GENIUS I/O (TRIO) (they have retracted their prior statement about a lifecycle change)
© ABB Group April 10, 2014 | Slide 16
© ABB Group April 10, 2014 | Slide 17
IndustrialIT System 800xA for MOD 300
The need to evolve.
© ABB Group Month DD, Year | Slide 18
1984
1988
1992
1996
2000
StationStation
S800 I/O
1994
MOD 300 DCSSC Controller w/ TRIO
MOD 300 DCSw/ Model B Controller
AC400 Series
Evolution through
Enhancement
Evolution without
Obsolescence
System 800xA2004
Control system evolution is: • The continuous process of updating
systems to current technologies so manufacturing operations remain
competitive in today’s global environment .
• An incremental process. • Based upon using your existing
installation as the foundation for change • Typically a systematic, on-going effort,
with a step-by-step approach is recommended.
Evolution Process Site Audit
System Overview
HMI Details
Controller Details
CPU Loading
Memory Utilization
Applications Running
EH Data
Number of Logs Sample Rates
Batch Data
Licensing Info
© ABB Group April 10, 2014 | Slide 19
Evolution Steps
Site Audit Report
Evolution Report
© ABB Group April 10, 2014 | Slide 20
Existing Control System - Solution Area
Notes
ABB
APP
Date: 9-11-06xxxx-xxxxCust. Ordr. No.
Sheet 1 of 1
Size B Rev. 1Drawing No.Cust:Scale: None
A
B
C
D
A
B
C
D
1 2 3 4 5
Revisions:
6 7 8
1 2 3 4 5 6 7 8
Dr. Phil Coutlon
Title:
ASIS June 2012EtherNetEtherNet – Fiber OpticRemote I/O
AC
460
CS
S 2
00
AC
460
CS
S 7
00
Futu
re C
SS
1100
OS/ES ASR 01
OSASR 02
OSASR 03
OSASR 04
OSASR 06
OSASR 05
Eng PC
Eng PC
IMSASR 08
OPC Server1100 Notes
1) All Unix Stations support 3 Clients.2) AdvaBuild ver 2.7/43) AdvaCommand ver 1.7/2
Risks of not moving Forward.
© ABB Group Month DD, Year | Slide 22
Single Point Failure in HMI’s could result in HMI being non recoverable.
ABB no longer supplies these items.
Ebay or equivalent is the only option, condition unknown.
Production Downtime Cost versus Project Cost.
Unplanned failure could impact production.
XXXX has experienced 2 hard drive failures per year for the last two years. RTA (Interface between HMI and Controllers) boards are only available only as refurbished units and the Unix station parts are scarce, used and 15 years old.
Evolution Plan
© ABB Group Month DD, Year | Slide 23
Notes
ABB
APP
Date: 06- 16- 12xxxx-xxxxCust. Ordr. No.
Sheet 1 of 1
Size B Rev. 2.0Drawing No.Cust:Scale: None
A
B
C
D
A
B
C
D
1 2 3 4 5 6 7 8
1 2 3 4 5 6 7 8
ASRCPhase 1 2013
Option 2Dr. Phil Coutlon
Title:
AC
460
CS
S 2
00
AC
460
CS
S 7
00
CS
S10
00
OSASR 02
Advacmnd 1.9
OSASR 06
Advacmnd 1.9
OPC Server 1100 Existing
Notes1) 1 Environment2) ASR 02, ASR 06 remain backup for x Months.
300 Tags 15 Graphics
MOD 300 Distributed Communications Network
1 2
3
AdvaBuild v 3.7Redundant Connectivity Servers
Primary Redundant Connectivity ServersRedundant Connectivity Servers
Primary Redundant Connectivity ServersRedundant Aspect Servers
Primary Aspect Servers
Primary Domain Controller
Redundant Domain Controller
4 5
6 9
7 8
10 11
12
13 14
15
16 17
18
KVM
IMS 6500 Tags
Eng 1 Opr
Eng 2 Opr
Eng 3 Opr
Eng 4 Opr
19
21
20 22
24
23
Evolution Plan Phase 1
© ABB Group Month DD, Year | Slide 24
Notes
ABB
APP
Date: 06- 16- 12xxxx-xxxxCust. Ordr. No.
Sheet 1 of 1
Size B Rev. 2.0Drawing No.Cust:Scale: None
A
B
C
D
A
B
C
D
1 2 3 4 5 6 7 8
1 2 3 4 5 6 7 8
ASRCPhase 1 2013
Option 2Dr. Phil Coutlon
Title:
AC
460
CS
S 2
00
AC
460
CS
S 7
00
CS
S10
00
OSASR 02
Advacmnd 1.9
OSASR 06
Advacmnd 1.9
OPC Server 1100 Existing
Notes1) 1 Environment2) ASR 02, ASR 06 remain backup for x Months.
300 Tags 15 Graphics
MOD 300 Distributed Communications Network
1 2
3
AdvaBuild v 3.7Redundant Connectivity Servers
Primary Redundant Connectivity ServersRedundant Connectivity Servers
Primary Redundant Connectivity ServersRedundant Aspect Servers
Primary Aspect Servers
Primary Domain Controller
Redundant Domain Controller
4 5
6 9
7 8
10 11
12
13 14
15
16 17
18
KVM
IMS 6500 Tags
Eng 1 Opr
Eng 2 Opr
Eng 3 Opr
Eng 4 Opr
19
21
20 22
24
23
Update ES
Evolution Plan Phase 2
© ABB Group Month DD, Year | Slide 25
Notes
ABB
APP
Date: 06- 16- 12xxxx-xxxxCust. Ordr. No.
Sheet 1 of 1
Size B Rev. 2.0Drawing No.Cust:Scale: None
A
B
C
D
A
B
C
D
1 2 3 4 5 6 7 8
1 2 3 4 5 6 7 8
ASRCPhase 1 2013
Option 2Dr. Phil Coutlon
Title:
AC
460
CS
S 2
00
AC
460
CS
S 7
00
CS
S10
00
OSASR 02
Advacmnd 1.9
OSASR 06
Advacmnd 1.9
OPC Server 1100 Existing
Notes1) 1 Environment2) ASR 02, ASR 06 remain backup for x Months.
300 Tags 15 Graphics
MOD 300 Distributed Communications Network
1 2
3
AdvaBuild v 3.7Redundant Connectivity Servers
Primary Redundant Connectivity ServersRedundant Connectivity Servers
Primary Redundant Connectivity ServersRedundant Aspect Servers
Primary Aspect Servers
Primary Domain Controller
Redundant Domain Controller
4 5
6 9
7 8
10 11
12
13 14
15
16 17
18
KVM
IMS 6500 Tags
Eng 1 Opr
Eng 2 Opr
Eng 3 Opr
Eng 4 Opr
19
21
20 22
24
23
Remove Unix Boxes replace with 800 xA
Evolution Plan Phase 3 Power House Addition.
© ABB Group Month DD, Year | Slide 26
Notes
ABB
APP
Date: 06- 16- 12xxxx-xxxxCust. Ordr. No.
Sheet 1 of 1
Size B Rev. 2.0Drawing No.Cust:Scale: None
A
B
C
D
A
B
C
D
1 2 3 4 5 6 7 8
1 2 3 4 5 6 7 8
ASRCPhase 1 2013
Option 2Dr. Phil Coutlon
Title:
AC
460
CS
S 2
00
AC
460
CS
S 7
00
CS
S10
00
OSASR 02
Advacmnd 1.9
OSASR 06
Advacmnd 1.9
OPC Server 1100 Existing
Notes1) 1 Environment2) ASR 02, ASR 06 remain backup for x Months.
300 Tags 15 Graphics
MOD 300 Distributed Communications Network
1 2
3
AdvaBuild v 3.7Redundant Connectivity Servers
Primary Redundant Connectivity ServersRedundant Connectivity Servers
Primary Redundant Connectivity ServersRedundant Aspect Servers
Primary Aspect Servers
Primary Domain Controller
Redundant Domain Controller
4 5
6 9
7 8
10 11
12
13 14
15
16 17
18
KVM
IMS 6500 Tags
Eng 1 Opr
Eng 2 Opr
Eng 3 Opr
Eng 4 Opr
19
21
20 22
24
23
Power House Addition Savings approx 250K
Consolidate Into CS 1100
a. 200 Ain b. 45 Aout c. 300 DI d. 100 DO e. 50 Graphics
Power House Incorporation into Existing Subsystem Savings
© ABB Group Month DD, Year | Slide 27
By utilizing existing existing Contoller Sub-System.
Hardware (Cabinets, Power Supplies labor cost, )
50K
Utilize the same ES,
97K Utilize the 800xA Components. Historian, Domain Controller etc.
100K
Total Savings 200K – 250K
Time Line and Impact on Production
© ABB Group Month DD, Year | Slide 28
Yr 1 Upgrade ES.
Executed at ABB
Downtime 8 hrs
Risk Low.
Phase 1 Phase 2
Upgrade Unix to 800xA
ABB/xxxx Project
Executed off site
Extensive offsite testing
Downtime Zero.
Risk Low.
Phase 3
Power House Addition.
Off site execution
Extensive Off Site Testing
Downtime 3 Days
Field wiring will extend this time.
Risk Low