Category: ABB

Importance of HMI

In control rooms of old, the number of alarms was limited by the amount of space

on the control room panel board and the cost of wiring equipment from the production area to the board.

Annunciators, indicators and switches (to acknowledge and clear a resolved alarm)

had to be essential to justify a place on the panel.

If a new alarm was needed, an existing alarm would usually have to  make way.

This began to change with digital signals and the distributed control system (DCS) in the 1980s.

Panel boards were replaced by monitors and servers,

and signals were transmitted from plant equipment to computer processors,

where the signals were turned into actionable information.

But the alarms were overloading the control room and terms such as flooding,

nuisance, chattering, fleeting and stale were coined to describe them and their effect on the operators.

The modern HMIs are equipped with high performance grayscale graphics,

using color carefully and provide effective alarm handling and analysis.

Leading paths to greater awareness, faster response and better decisions

Handling the unplanned outages has become the number-one priority for many companies today.

On an average, operators deal with thousands of alarms per day. 

Hence, they should face no more than two alarms per 10-minute period

but alarm overload distracts the operators and often causes unplanned downtime.

For maximum plant performance, high performance HMI and advanced alarm management

helps to improve the operator’s tools and work environment.

An ABB case study reveals savings of more than $800.000 from upgrading to a high performance HMI.

• Bubble-up alarming allows the alarm with the highest priority to ‘bubble up’ 

above lower priority alarms associated with the same device

• Integrated help displays in the form of pop-ups

• Extendable faceplates put all the information the operator needs in one place

• Level 1 surveillance of the entire plant or unit in one graphic to facilitate

rapid visualization of the entire process, as well as KPIs

• Level 2 visualization of specific parts of the process, providing alarms,

information and controls for each area and easy navigation to level 3 graphics (P&ID style displays)

• Alarm macros for condition-based alarming, if each alarm condition needs to be managed individually

System 800xA extends the scope of traditional control systems

to include all automation functions in a single operations and

engineering solution. The result is significant improvement in

process control as well as production management, smart

instrumentation, smart drives and motor control, information

management, asset optimization and documentation.

The Advant Master systems provide the flexibility to implement

System 800xA functionality in an incremental fashion. Others

promote ‘rip-and-replace’ migration strategies, while ABB delivers

genuine system evolution, allowing Advant Master users to build

on their strong DCS foundation. New functionality can be added

at a pace that’s tailored to user needs. 

■ Maximum return on investment

For Master DCS and Advant OCS with

Master software systems, ABB offers

evolution strategies to ensure maximum

return on investment while enhancing

equipment availability and performance.

ABB’s systems are designed to be backward compatible, protecting existing

investments in Advant Master and

ensuring cost-effective strategies for

extension and growth.

This enables Advant Master controllers,

network, I/O and field wiring to be retained

when upgrading to newer user interfaces.

Being competitive in today’s business environment requires

continuous productivity improvements. ABB has combined Advant

Master (Master DCS and Advant OCS with Master software systems)

with IndustrialIT Extended Automation System 800xA productivity

enhancement software. This provides Advant Master users with

the technology and solutions needed to achieve sustainable

competitive advantages by enabling plants to perform smarter

and better at lower costs.

Overview

Features and Benefits

■ Advant Master extended with

System 800xA for growth and

non-stop performance

Reducing time to decision and action

System 800xA Process Portal delivers

the exact information, filters out noise

to facilitate consistent, sound business

decisions, and provides the right tools

for the relevant user to take action as

quickly as possible

Optimizing plant asset availability

and performance

System 800xA real-time Plant Asset

Management features increase in process

uptime while reducing costs through

predictive and proactive maintenance.

Control, I/O and fieldbus for all plant needs

System 800xA offers a comprehensive

controller suite of standards-based hardware and software as well as a complete

line of industrial I/O for all plant needs.

System 800xA integration of all major

international standard fieldbuses offers

lower lifecycle costs through cost savings

in design, implementation and operation

of field equipment.

Equipment overview

•4 central units per rack, T200 offers a choiceof 4 central units graduated in performancewith the same instruction set

•RAM and EPROM memories with differentmemory capacities

•3 basic module racks in 2, 5 and 8 slotconfigurations

•3 expansion module racks with 4, 7 or 10 l/0slots

•Descrete input and output devices availablein common voltages

•Analog input and output devices for voltageand current

•Input devices for temperatures

•Interrupt input device, fast counter,positioning device

•Modules for central and decentral coupling ofexpansion module racks

•Interface equipment

•Couplers for the ABB Procontic field busZB10, ABB Procontic T200 bus ZB20, andPROFIBUS

•High-performance industrial computer

Efficient and easy-to-program serial bussystems connect separately located stations

The ABB Procontic field bus, ZB10, ex-changes process data with the other ABBProcontic systems.

The ABB Procontic T200 bus ZB20 is de.signed specially for data exchange betweenABB Procontic T200

stations, transportingparameters, and downloading programs.

Serial interfaces on the communication processor are also available for transfer ofprograms and signal

states to an operatingstation.

An ABB Procontic T200 control consists, in itssimplest form, of a module rack, a central unit,program

memory, an input module, an outputmodule, and a power supply unit.

Expansion module racks provide ample roomfor further input and output devices. 

Fourcentral units classified according to their ex-pandability and a series of pre-processors andinterface

equipment enable optimum adaptationof the ABB Procontic T200 to the respectivecontrol task. 

The T200 can be configured cen-trally (in the immediate vicinity) or decentrally.

Automation System ABB Procontic T200.

Modular, powerful, decentrally expandable

The ABB Procontic T200 automation system isa modular control system that largely satisfiesthe

requirements of today and tomorrow.

Thanks to its rack based architecture and widerange of modules, the ABB Procontic T200 canbe

assembled to suit most any application.

The simple handling and planning of thesystem saves time and money.

ABB Procontic T200 programming software islBM-compatible and provides efficient processdisplay, PLC

operation, and connection to fieldbuses.

ABB Procontic systems are designed for heavy-duty industrial operation and are distinguishedby their

resistance to interference (EMC).

Extensive diagnostic functions of the ABBProconticT200 simplify commissioning andtroubleshooting of

the system.

Advantages with ASTAT®:

• Fewer and better components result in more up-time.

• Operational diagnostics will speed-up fault tracing.

• Multipurpose spares will reduce parts in stock.

• The PC-program for maintenance can be installed in

a ground level computer. Nobody has to visit the crane

first to find the problem.

Digital ASTAT motion control is superior to other

techniques and it increases the operational results to the

limits of the crane itself. For you as a user it will create:

• Increased productivity. The operator moves the

crane without jogging, i.e. with one single movement.

• Prolonged lifetime. Smooth acceleration and

retardation decreases torque peaks.

• Special functions reduce rope and brake wear.

• Satisfied operators. Motion control is possible down

to increments of only one cm. Try to do such a small step

without the ASTAT system!

• Excellent control features permit higher speed

during automatic control.

When to select ASTAT® ?

ASTAT is suitable for crane control in demanding

environments, when larger motor powers must be

handled, for retrofits or when automating one or more

cranes.

The ASTAT Digital Crane Motion Controller has

better control and information properties

compared to earlier controllers. Equally

important is the focus on quality of hardware

components. The digital controller can be

mounted on a steel plant crane in hot countries

such as India without extra cooling or air

conditioning. This capability provides additional

benefits to worldwide industrial crane users.

i.e. The crane control system must withstand

dirty, hot and cold environments in addition to

difficult power supply systems. This has forced

us to integrate functions like brake control, time

relays, logic control and thermistor relays into

the ASTAT controller. Generic products with the

same robustness as the ASTAT controller are

difficult to find. With this level of integration we

offer a complete, fully tested motion control system.

Slip-ring motors may be produced with small

internal rotor losses. This is important in crane

applications with multiple motors and a high

demand for good motion control. As well as

being ideal for crane applications, slip-ring

motors are low on maintenance with brushes

being exchanged only every 5 to 10 years.

ASTAT uses the slip-rings for measurement of

the rotor frequency and from this calculates the

speed. In most cases no tachometer or pulse

encoder is necessary.

The operator controls the crane motion, while

all rotor contactors are optimized by ASTAT, as

an integrated part of the current control. This

results in dramatically reduced wear of

contactors and crane mechanical parts. Crane

maintenance costs will therefore be reduced.