ABB Corporate Research. Integrating Automation. Dr. Ulrich Topp Dr. Dirk John ABB - 1

Transcription

1 ABB Corporate Research Integrating Automation Dr. Ulrich Topp Dr. Dirk John ABB - 1

2 What are we talking about? Scope of Problem: information technology vs automation needs in the domain of integration devices into process control systems Example of integration approach ABB System 800xA Requirements from the user application NAMUR NE105 Challenges and vision Software complexity Common device model as a catalysator for integration ABB - 2

3 Software Included Automation levels ABB - 3

4 Long-Term Viability of Device Integration 5 to 10 ys 10 to 15+ ys 4 to 5+ ys 10+ ys 3 to 4 ys Factory Automation Factory Automation Factory Automation Process Automation DCS/SCADA DCS/SCADA DCS/SCADA Windows technologies/interfaces Windows technologies/interfaces Win OS, PC HW Windows techn./int. Win OS, PC HW Win OS, PC HW Win OS, PC HW Win OS, PC HW ABB - 4

5 Integration Engineering Devices Optimization Operations 0 7 Control Process control system ABB - 5 Integration is synonymous with making the information and functions of devices (entities) available and accessible for various tasks in the life cycle of a system, e.g. During the engineering process for configuration and parameter assignment During plant operation, e.g. for monitoring alarms and asset management

6 Device The scope is based on definitions in ISO 15745: Device entity that performs control, actuating and/or sensing functions and interfaces to other such entities within an automation system Device profile representation of certain integration aspects of a device Device integration model The device integration model describes the properties of the device that are necessary to support the application requirements defined in the process integration model and the information exchange integration model e.g.: function(s) performed by the device; input and output data exchanged with the device; configuration parameters and runtime variables stored by the device. ABB - 6

7 Device Integration - Evolution System Device Integration System Device Functionality System HART Device Advanced diagnostic Predictive performance & maintenance data Asset monitors Electronic documentation Traditional Value HART Value Device Parameter Time ABB - 7 All values Quality Signal De-central Functions Distributed Control Device-to-Device communication DTMs 4-20mA SMART Fieldbus Industrial IT

8 Expectations on Device Integration Technology Optimization Engineering Operations Diagnosis Maintenance Calibration Configuration Parameterization Commissioning 0 7 Operation Display Alarm signals Controller Seamlessly integrated into control system Access to device internal data Openness for all device manufacturers Easy to use Process variables Time synchronization Status Devices ABB - 8

9 What are we talking about? Scope of Problem: information technology vs automation needs in the domain of integration devices into process control systems Example of integration approach ABB System 800xA Requirements from the user application NAMUR NE105 Challenges and vision Software complexity Common device model as a catalysator for integration ABB - 9

10 Example: ABB System 800xA System integration makes external tools obsolete Fieldbus topology planning Fieldbus application configuration Field device parameterization and diagnostics Device Asset Optimization Easy navigation through plant explorer and context sensitive menus All field device aspects are only one mouse click away ABB - 10

11 Device Type Object with its Aspects Real Object Each device type object includes aspects for Product Documentation Configuration Commissioning Operation Maintenance Management Parameterization Asset Monitoring Diagnosis ABB - 11 Object Type, delivered by Device Integration Center with Device Library

12 Represented in different Object Structures Functional Structure Asset Structure Control Structure Milko Chemical Solid Processing Liquid Processing Mixing Unit BV1 Mixing Unit BV2 BV2TemperatureControl BV2QuantityControl BV2ProductTransfer BV2Agitation BV2MilkSupply FIC201 FIC201FlowTransmitter FIC201Valve FIC201 Flow Control EU201 BV2Additives MilkDistributionManifold ProductDistributionManifold Milko Chemical AdditiveWarehouse LiquidProcessing ControlRoom ElectricalRoom Controller 1 ProcessingArea EU101Motor EU201Motor FIC101Valve FIC201Valve FIC101FlowTransmitter FIC201FlowTransmitter MixingUnitBV1 MixingUnitBV2 B3, Packaging Control Network Milko, Control Project Applications Application 1 Control Modules FIC201 Flow control... Controllers Controller 1 Application Reference Hardware PM860 / TP830 Ethernet... Modulebus AI810 AO ABB - 12 Controller 2

13 Device Driver Integration Device Description (DD) All Instruments have a DD file for all communication protocols. These files provide a basic textural interface for device configuration in ABB and 3 rd party systems Device Type Manager (DTM) For all HART & Profibus devices, ABB devices provide a DTM configuration tool. This DTM is an open standard supported by ABB and many 3 rd party systems. The DTM allows an advanced, graphical, user friendly interface and incorporation of high sophisticated functions ABB - 13 DD DTM

14 Ease of Use Optimized maintenance workflow reduces time to action Continuous Condition Monitoring Fault Condition Reporting Alarming Visualization Access to detailed diagnostic Fault Report Submitting into CMMS Work order information in 800xA Analyzing Reporting Decision Submit Action ABB - 14 Monitoring

15 Summary Integrating Automation Integrated information featuring a single access to all plant information and an integrating system architecture. Efficient engineering through one-time data entry, automated object creation and easy re-use of existing solutions. Highly scalable therefore being the optimum solution in all situations, from the smallest to the largest applications and devices. Open communications thanks to standard systems, commodity components and common fieldbus technologies. Unrivalled scope providing a vast range of interoperable products and systems ABB - 15

16 Device Integration based on open but often competing Standards IEC parts Foundation Fieldbus PROFIBUS IEC (Electronic) Device Description (Language) Dialects of this are actually used by the different protocols HART Field Device Tool Interface Device Driver concept independent of fieldbus protocol Specifying software interfaces and behavior of device drives as well as hosting tool environment OLE for Process Control... ABB - 16

17 What are we talking about? Scope of Problem: information technology vs automation needs in the domain of integration devices into process control systems Example of integration approach ABB System 800xA Requirements from the user application NAMUR NE105 Challenges and vision Software complexity Common device model as a catalysator for integration ABB - 17

18 NAMUR Recommendation NE105 Specifications for Integrating Fieldbus Devices in Engineering Tools for Field Devices NAMUR-AK 2.6 Feldbus ABB - 18

19 ABB - 19 NAMUR Recommendation NE105 - Content Long-Term Viability of Device Integration Investment Safety Version Conflicts User Interface Specifications & Style Guide Integration of Devices (Installation & Removal) in Configuration Tools User Guidance Display of Devices Standard Profiles Functional Specifications for Device Connections and Interfaces for Device Data Processing Device Descriptions Licensing of Device Descriptions Cross-Platform Compatibility Full Support of Device Functionality Standardized Data Filing Certification

20 Full support of device functionality Openness and system integration Integration of all field devices, IOs, drives, motor controllers, etc. creates modular, transparent architectures Standardized integration of process field devices (simple/medium complex) in asset management Function Block technology for control in the field in multi vendor systems Standardized communication for process variables, status and diagnosis information Acyclic comm. Asset mgt. Cyclic comm. Process control EDDL ABB - 20

21 ABB - 21 NAMUR Recommendation NE105 - Content Long-Term Viability of Device Integration Investment Safety Version Conflicts User Interface Specifications & Style Guide Integration of Devices (Installation & Removal) in Configuration Tools User Guidance Display of Devices Standard Profiles Functional Specifications for Device Connections and Interfaces for Device Data Processing Device Descriptions Licensing of Device Descriptions Cross-Platform Compatibility Full Support of Device Functionality Standardized Data Filing Certification

22 Long-Term Viability of Device Integration 5 to 10 ys 10 to 15+ ys 4 to 5+ ys 10+ ys 3 to 4 ys Factory Automation Factory Automation Factory Automation Process Automation DCS/SCADA DCS/SCADA DCS/SCADA Windows technologies/interfaces Windows technologies/interfaces Win OS, PC HW Windows techn./int. Win OS, PC HW Win OS, PC HW Win OS, PC HW Win OS, PC HW ABB - 22

23 ABB - 23 Long-Term Viability of Device Integration

24 What are we talking about? Scope of Problem: information technology vs automation needs in the domain of integration devices into process control systems Example of integration approach ABB System 800xA Requirements from the user application NAMUR NE105 Challenges and vision Software complexity Common device model as a catalysator for integration ABB - 24

25 Manage SW complexity Effort Old method New method Methodology UML Developers handbook Process Common process with templates, checklists Tools Reuse Enabled by component based development id UHTE System Component Name: Package: Version: Author: 2 nd user UHTE System Component Component Model 1.0 Alexander Nyßen << FAST_PATH >> Notification «coordinator» :SystemCoordinator «system» UHTE Update SensorBoardControl SignalProcessing AnalogOutput sensorboardinterface : SensorBoardInterface << CONFIG_PATH>> SensorBoardControl << FAST_PATH >> CalculatePressureAndSensorT emperature «data analysis» pressuresignalprocessing : PressureSignalProcessing LifeCycle EntityAccess «i/o subsystem» HMI :Subsystem <<FAST_PAT H>> CurrentOut Complexity Diagnosis << CONFIG_PATH >> Calibration <<CONFIG_PAT H>> Calibration currentoutput :AnalogOutput From System Design down to source code and other required assets like device descriptions, HMI, asset monitors Common repository to share work results LifeCycle EntityAccess Diagnosis LifeCycle EntityAccess Diagnosis LifeCycle EntityAccess Diagnosis Common Framework Common Components ABB - 25

26 Use case groups related to field devices ud UCG Installation ud UCG Configuration automation system Installtion of single Object Type ud UCG Control Application Engineering Prepare Object instancing cd UCG Commissioning: Paramter handling automation system Access Upgrade Dev ice object automation Information type replacing system Setup of module existing ud UCG configuration Maintenance functionality «include» Automation System Dev ice Installation engineer Control App Engineer Commissioning ud UCG Operation Engineer Update object type with additional functionality connect primary signal to Create control Obj application ect Instance v ariable automation system automation system Dev ice Set dev ice parameters (offline) Superv ise health status Dev ice «trigger» Go Online Configure Asset Dow nload Change «trigger» Upload parameter Online compare Monitor Transfer parameter set configuration set parameter set parameter set (cylcic & a-cyclic) Operator (cyclic & a-cyclic) «trigger» Configure CMMS «include» connectiv ity «include» Configuration Engineer «include» «include» «include» «include» Configure DMS Go Online connectiv ity Observ e Primary Signal «include» «include» CMMS Perform self diagnosis DMS Go Online Notify on abnormal status old device Dev ice «trigger» Dev ice Operator Service Staff «trigger» Schedule serv ice task ABB - 26 UCG Network Engineering UCG Network management Observ e control application v ariable Dev ice Schedule and perform calibration HART IO Module CMMS DMS

27 Device Development a comprehensive view Idea: Device Model, which describes and delivers Software oriented aspects of a device such as sub-systems, entities, state machines Aspects required for system integration (Device as system component). Version Management for all aspects of the device and all related to the device in the system Generate artefacts relevant for device construction (code, state machines, Hart layer 7 ) Generate artefacts relevant for system integration (DDs, Asset Monitors, Function Blocks ) Safety Assessment Function Blocks Visual Device Descriptions (DD, GSD ) HMI Tree UML based Device Model Diagnosis Sensor Interface Device Coordinator Documentation Hart Hart Modelling Device Asset Monitors Input for DTM Code Generation of ordinary subsystems ABB - 27 Device Model Core Environment Assistants

28 What did we talk about? Scope of Problem: information technology vs automation needs in the domain of integration devices into process control systems Example of integration approach ABB System 800xA Requirements from the user application NAMUR NE105 Challenges and vision Software complexity Common device model as a catalysator for integration ABB - 28

29 ABB - 29

30 Enhanced DDs (edd) User Interface Show Pictures Generate Data-driven Plots Trending and bar-graphs of live device data Tabbed Dialogs and Windows (Supports full screen PC GUI's) Other Enhancements Simplified development of Methods Improved error handling/status (INFO, WARNING, ERROR) Default values for simulation and offline configuration ABB - 30

31 Because Styleguide - Spezifische und generische DTMs Eine wachsende Anzahl an spezifischen DTMs ist neben aus DDs generierten DTMs verfügbar In Zukunft gemäß des FDT Styleguide ABB - 31 Das User Interface der EDDs wird bisher weitestgehend vom Host System bestimmt