Seal of approval
New version of ABB’s 800xA control system with integrated safety functions

ABB is staking out its territory in the process automation market. The new version of its 800xA automation software offers improved safety and production management features. From the organizational standpoint, many users will be interested to find out that the new version can replace four old ABB control systems, and the company is already taking aim at competitors’ products.

Companies are ramping up investment in automation equipment again. Experts expect that the total market will grow by 5.1% over the next five years, from $50 billion (2003) to $64 billion (2008). Part of the money will be sent on real time capability, and demand will remain strong for intelligent field devices and new control systems. In keeping with this trend, ABB has upgraded its 800xA system and has introduced a new version at this year’s Hannover Fair/Interkama. The new version has already been certified by the TÜV Süddeutschland testing agency/Germany.
The decision to integrate four of ABB’s ten control systems is a major step forward. ABB wants to present a uniform
face to users and ensure that older programs will continue to provide viable solutions in the future. The system comes with integrated MES modules including material tracking, quality management, production management and a module for the weighing and apportionment processes. The company says that users also
have the option of adding third-party modules, and they also indicate that seamless transition from third-party systems to the 800xA may be possible in the not too distant future.

Either combined or separate
Another new feature facilitates the design of a flexible, scalable Safety Instrumented System (SIS) which reduces risk to humans, equipment and the environment. In addition, the 800xA High Integrity package offers a scalable SIS which conforms to IEC 61508 and IEC 61511. It addresses the entire safety control loop including SIL-certified AC 800M controllers, field devices, I/O modules, sensors and actuators. Depending on application requirements, the user can either combine automation and safety functions in one controller or keep them separate. Dow Chemical, which has long-term supply and service agreements with ABB, takes advantage of this flexibility: “We use standardized tools in our company,” explained Edward R. Sederlund, Process Automation Product Manager at Dow Chemical. “The 800xA high integrity controller, I/O modules and ‘same but separate’ architecture enable us to substantially reduce our life cycle, project design, engineering and modification costs without affecting our ability to comply with safety requirements.”
On the 800xA, the process control and safety-related functions are executed in the same system environment and even in the same controller, ensuring that applications interact safely in real time. The manufacturer claims that the architecture eliminates duplication of engineering effort and significantly reduces the associated life cycle costs (project engineering, training, operating, maintenance and spare parts management).
Real time tracking of material
Manufacturing management enhancements facilitate real time tracking of material throughout the warehouse, the labs and the production area. The information displayed by the Operator Interface Process Portal can be used to manage and maintain the different batches. The software also includes functions for tracking stock level changes. The program captures and stores production information which can be used to generate consolidated reports. The Real Time Production Intelligence Module (Real-TPI) is designed to enable the company to identify opportunities for productivity improvements based on data extracted from ongoing production. ABB employees report that manufacturing companies in various industries
have achieved good results using these functions. The data is presented in a user-friendly format and is typically used to eliminate production bottlenecks. This enables users to improve both line throughput and product quality.
Pulling together and optimizing
The “Integration” module helps customers reuse system information, for example data on instrumentation, I/O configurations, wiring drawings and PID drawings. The module uses information from Intools (Intergraph) about the control loop structure to build the 800xA database. A stored, pre-defined allocation file provides the basic framework which correlates Intools control loop types with 800xA objects. Document links are generated, maintained and updated to provide context-sensitive navigation in Intools design documents, for example control loop diagrams, CAD documents and instrumentation specifications. Integration between 800xA and Intools provides a uniform
data source in the system, which makes engineering easier throughout the entire life cycle of the system. After commissioning, changes (e.g. alarms, measurement ranges, units of measure, etc.) can be played back in Intools.
This helps maintain design consistency which minimizes costs that would otherwise be associated with searching for inconsistencies. It also reduces the reluctance to initiate future system optimization projects. The experts at ABB emphasize that this approach reduces management costs on an ongoing basis, because design and engineering data are synchronized. This improves data reliability and reduces cost. Dynamic access to system engineering design documentation is guaranteed at any time, which is another advantage.
The Industrial IT Training Simulator is designed to help users train their system operators and maintenance personnel, test and validate control applications and test parameter adjustments for system optimization. Various aspects of simulation are combined in one system, and this can significantly reduce investment costs. ABB says that a whole range of new functions including device management tools in particular will be released in the coming months. All automation functions are then consolidated in a single operating and engineering environment. The company also says that it may be possible to link to (and replace) third-party control systems