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ABB Industrial'T System 800xA Harmony/INFI90 System

Features and Benefits

Extending the Return-on-lnvestment

of Harmony Systems: New system

hardware and software releases increase

operating efficiency and extend the life of

installed systems. New products and pro-

grams make the decision to evolve existing

systems straightforward and easy.

Achieving an Extended Automation

scope with System 800xA:

- Personalized User Workplaces:

Reduced time to decision and action

is achieved with 800xA Process Portal

personalized workplaces.Information

and workplace layouts are optimized to

maintenance, engineering, management,

and operating personnel preferences and

needs.

- Wide-ranging control functionality:

Applicable for control and safety

applications, AC 800MControl and

I/O meet all plant automation needs.

AC 800M integration with Harony

systems is made easy through the INF190

Function Code (FC) Library and peer-

to-peer comm unications with Harmony

controllers.

- Device Management: Device Manage-

ment features lower lifecycle costs through

significant savings in the design, implemen-

tation, and operation of field equipment.

- Asset Optimization:Significantly

increase process uptime and reduce

maintenance costs through optimized

remediation work processes and early de.

tection of asset performance problems.

-Information Management: Improve vis-

ibility of integrated information results in

effective decision-making.

Lowering System Lifecycle Costs

and Risk through System Evolution:

Evolution programs ensure that automa-

tion systems are continually optimized to

support customer business goals.

To be successful in today's highly competitive business markets,

companies drive their production facilities toward Operational

Excellence (OpX) with defined goals of maximizing Return on Net

Assets (RONA), lowering Total Cost of Ownership (TCO), sharing

best practices throughout the enterprise, and driving profitable,

sustainable growth. Achieving these goals require more than what a

traditional Distributed Control System(DCS) can offer. It requires a

plant automation system that can improve:

Plant effectiveness - the ability to combine the right decisions

with optimized work processes

Plant agility - the ability to make 'on-the-fly’ adjustments as busi-

ness opportunities present themselves with the same

proficiency as when performing the routine

Performance visualization- the ability to provide users with real-

time performance and feedback

In general, OpX can only be achieved by extending the reach of

plant automation systems to synchronize all process operations

within one common environment for operations, engineering, and

information.

ABB delivers this extended automation scope by combining the

SYMPHONY Harmony system with Industrial IT Extended

Automation™ System 800xA's best-in-class productivity enhancement

software. System 800xA Asset Optimization,Information

Management, and Process Portal personalized workplaces optimize

productivity at substantial cost savings. Where others promote

“rip-and-replace" migration strategies, ABB delivers true system

evolution allowing Harmony owners to build on their strong DCS

foundation by providing the flexibility to implement these functions

in an incremental stepwise fashion.

SYMPHONY Harmony is a proven process control system used for demanding

applications in various industries. The wide range of Harmony references includes the

power generation, chemical, pharmaceutical, pulp and paper, water and wastewater,

petrochemical, metals and mining, food and beverage, cement, and sugar industries.

These system owners first acquired their ABB distributed control system because

it offered the best set of solutions that helped them be successful and competitive.

Whether it was ease of engineering, system scalability, powerful control applications

or ergonomically designed user interfaces, the system met the company's needs in an

effective and efficient manner.

But markets and business conditions are constantly changing,requiring faster

turnarounds, greater customization, smaller lot sizes, and lower overall costs. In

today's faced paced economy, companies are under more pressure than ever to run

their operation profitably - to achieve greater results with fewer resources.

With reduced capital spending, ABBsystem owners need to perform smarter and

better at substantial cost savings. The business challenge they face is to squeeze the

most productivity from the installed system by adding new functions and features,

extending its useful life and the applications within it, and by reducing maintenance

costs while improving overall reliability.

ABB addresses these challenges by providing new capabilities that enable Symphony

Harmony system owners to achieve Operational Excellence. Symphony Harmony

system products are enhanced to improve their cost/performance curves and make

them more reliable while incorporating proven, new technology to enable step change

benefits.

While a greenfield automation system installation can readily take advantage of the

latest capabilities, an existing system installation faces many modernization challenges.

These include:

24/7 production, short or non-existent downtime

Upgrades must be performed without jeopardizing operation of plant or mill

Maintenance budgets rather than large capital project funding

Site has made significant investments in:

.Control applications

.User interfaces

·Training of plant personnel

.Standard Operating Procedures (SOP) based on the automation system

.Validation (for the regulated industries)

.Hardware

.Software

.Other intellectual property

Therefore, changes to an existing system must be limited to the specific area of

interest, be risk averse, and protect the owner's investments in hardware, software,

and intellectual property: In short, there must be a solid, measurable Return-on-

Investment (ROI).

ABB's answer to these issues is founded in its evolution strategy. Evolution is ABB's

way to deliver continuous improvement to its installed systems; allowing system

owners to meet automation system business objectives in an incremental way affording

the lowest risk and best ROI. It is not migration, it is not “rip-and-replace"; it is a well

thought out plan, allowing system owners to adapt new capabilities at their pace,

according to their need.

From a product point of view, this strategy is business as usual at ABB. Its pledge

of Evolution tbrougb Enbancement (Figure 1) has extended the life and the

Return-on-Investment of installed Harmony systems. Other vendors may talk about

investment protection, but ABB's proven programs are truly unique in the industry. All

told, from the introduction of Network 90® in 1980, through each of the evolutionary

steps of INFI 90*, INFI 90 OPEN, and SYMPHONY"Harmony, this family of systems

represents the largest contiguous installed base of any process automation system

in the world. System 800xA represents the most recent step in the on-going system

evolution process.

The purpose of this document is to summarize the many opportunities available

to the Harmony system owner for enhancing the value of and extending the useful

functionality of their system. On the following pages are details of the enhancements

available to the Harmony DCS foundation (see section“Extending the Return-on-

Investment of Harmony Systems"); as well as the opportunities available to build to an

extended automation scope from a Harmony DCS foundation (see section“Achieving

an Extended Automation Scope with System800xA").

ABB continues to add traditional DCS functionality for the Harmony system. This has

resulted in a variety of new functions and technology updates for Harmony products

including Rack I/O modules, Bridge Controllers, communication modules, Composer

system configuration tools, and operator consoles. The following sections summarize

the most recent enhancements to the Harmony system.

Harmony Control,

The Harmony Rack modules (Figure 2) redesigned with modern board components

I/O, and

and surface mount technology, are form, fit, and functional equivalents to the

Communications

Network 90, INFI 90, and INFI 90 OPEN modules. This provides backward

compatibility to ensure a long lifecycle for Harmony systems.

Figure 2.Harmony Rack Modules

Harmony Rack Controllers. Harmony Rack controllers have remained state-of-the.

art through annual software and hardware enhancement releases. Following ABB's

commitment to Evolution tbrougb Enbancement, the system's flagship controllers,

the Harmony Bridge Controller (BRC) family, preserve existing system control logic

configuration including support for all existing function code executions,custom

user programs, and foreign device interfaces. This provides a predictable and risk-free

evolution for the system's control execution environment.

The BRC300and the BRC400 (Figure 3) represent the latest additions to the

BRC family.

Harmony BRC Controller Features

Form, fit & functional equivalent for Harmony rack controllers

Deploys advanced Reduced Instruction Set Computer (RISC) microprocessor

technology - Motorola32-bit Coldfire

Retains Harmony controller (BRC, MFP,etc.) hardware and software architecture

Enhanced controller reliability

Provides approximately (2x) function code execution rate vs.BRC100,(4x) vs.MFPxx,

and (8x) vs.MFCxx

Extended user configuration memory;30,000 function blocks(BRC400 version)

Preserves existing control logic configurations, providing predictable and risk-free evolution:

Function code execution

Custom user programs

Foreign device interfaces

■Fast fail-over redundancy

High availability and fault tolerance in a redundant pair configuration

Controller configuration supported by the Composer engineering tool

Supports all Harmony l/O systems, simultaneously providing support for installed I/O systems

and expansions:

Rack I/O

Block I/O

S800 I/O(System 800xA)

Support for Module Bus and Controlway communications

Figure 3.Bridge Controller Family(BRC300,BRC400)

Harmony Rack I/O. The Harmony Rack I/O family includes a wide variety of input,

output, and signal conditioning modules. Module types, ranging from standard analog

and digital I/O to specialty I/O such as turbine control, and Sequence of Events(SOE),

can be combined to provide a comprehensive set of functionality to meet all market and

industrial requirements. Additionally, the Harmony remote I/O capabilities have been

enhanced with the addition of S800 I/O (see section“S800 I/O for Harmony" for details).

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