Experience the Power of Integration!
Today's technologies provide unprecedented integration capability for much more access to information throughout the plant than ever before; the integration of previously isolated systems offers tremendous opportunities to improve all aspects of the manufacturing operation. The materials in this Knowledge Center discuss the integration possibilities available today, and demonstrate how information from previously disconnected areas can be harnessed and used to improve efficiency and profitability.
Top Stories
In order to be competitive, various plant entities, departments and personnel have to work as one flexible, integrated, collaborative team. For this to be accomplished, an automation platform with incredible connectivity capabilities is necessary. Integration of systems and applications where all actionable information is available for use in the system can be provided to users in a variety of roles.
System 800xA Extended Automation is an integration platform with unparalleled connectivity to enterprise and plant systems, applications, and devices that improves operations, engineering, control and maintenance and provides a collaborative environment where real-time decision making is a reality. This is the Power of Integration. Read more.
More than 30 years ago, the Dow Chemical Co. embarked on what ultimately evolved into a global corporate initiative: to develop and broadly leverage a standardized, highly integrated process automation system, incorporating basic process control, process information, and safety-system functionality. Download this document to learn why Dow chose ABB to form a collaboration that has successfully moved their operating discipline forward.
Control Article Series with Dow
As the collaborative development relationship between Dow and ABB continues to grow, the process industries stand to benefit from the commercial availability of even more capabilities that support Dow's operating discipline. In this article, a team from Dow Chemicals shares its perspective and techniques for developing its own process automation and safety systems, lessons learned, and why it took the path it did. Read more.
Key Articles
Process automation is essential to operating any complex production process. The sophistication and power of process automation enables vastly improved productivity, quality and cost control. Download now.
As existing oil and gas fields mature, they require new strategies for monitoring, asset management and maintenance. The Integrated Operations offerings from ABB help address these challenges. Download now.
Operator effectiveness is a fundamental element for sustaining the economic value of process control and management. It can be improved by empowering operators through improved situational awareness and better handling of abnormal conditions. Download now.
See how ABB's scalable multi-purpose solution meets the requirements of a truly integrated PAT solution. Read more.
Birds know when to fly south for the winter, but how do automation engineers figure out when it's time to migrate? Read more.
Process automation's end game is an integrated suite of applications extending from design engineering to maintenance and asset management functions, encompassing the ability to control, integrate and document myriad processes. Read more.
The industrial giant's focus on power and productivity puts it squarely in the frenzied center of global industrial and infrastructure investment. Read more.
The ABB Group
ABB is a global leader in power and automation technologies that enable utility and industry customers to improve their performance while lowering environmental impact.
Where to find us.
Featured White Papers
Choose an automation infrastructure that will boost performance today and readily adapt to tomorrow's demands. This paper provides a view on the possibilities. The potential and the power of integration lies in what can be achieved when information is made available, in context, to all of the devices, systems and individuals responsible for controlling, maintaining and managing production. Download now.
Process automation is essential to operating any complex production process. The sophistication and power of process automation enables vastly improved productivity, quality and cost control. Download now.
A central problem in plant operations as well as asset lifecycle management is that you need a way to keep together, manage, and have access to information about all different aspects of a great number of plant and process entities (objects). In a system that integrates automation, information, and collaborative business processes across the enterprise, each of these real world objects needs to be described from several different perspectives. Aspect Objects provide the solution to this problem. Download this white paper to find out how. Download now.
Providing a comprehensive overview of the state-of-the-art in Collaborative Process Automation Systems (CPAS), this book (published by ISA in 2009) discusses topics such as engineering, security, enterprise connectivity, advanced process control, plant asset management, and operator efficiency. This in-depth reference focuses on the differences between a CPAS and traditional automation systems. Implications on modern automation systems are outlined in theory and practice. This book is ideal for industrial engineers, as well as graduate students in control and automation. Buy Now.
This ARC Advisory Group white paper demonstrates the economic impact and improved business performance to be obtained by integrating the traditional domain of process control with IT technologies and applications. Download now.
In this white paper learn key strategies for achieving better return on assets through the extended use of automation. Download now.
Featured Products
Removing the barriers of traditional distributed control systems, System 800xA provides the integrated environment that is required to increase productivity while reducing risk and total cost of ownership.
System 800xA delivers the exact information and collaboration environment necessary for the formation and execution of sound business decisions. ABB's integration architecture, based on Aspect Object technology, relates all of your plant data, the Aspects, to the specific plant assets, the Objects. This architecture enables one click navigation, efficient engineering and presentation of the right information in the right context to the right user. Read more.
Featured Webcast
Whether for a unit retrofit or a grass–roots project, choosing the right process automation platform is a complex and important decision that will affect your productivity and profitability for years to come. Skimp up–front, and extra integration and maintenance tasks will soon eat up any initial cost savings. Aim too high, and you'll long be paying for overly complex functionality you don't need and will never implement. In this ControlGlobal.com webinar, you'll learn to cast process automation system costs in the context of a system's full life cycle, matching system capabilities against application performance, engineering and maintenance requirements. Register now.
Elimination of Common Cause Failures in Integrated Control & Safety Systems
Many process automation systems (DCS and PLC alike) incorporate Safety Instrumented Systems (SIS) as an integral part of the system. These systems are Safety Integrity Level (SIL)-certified, exactly like older, separate systems. In order to illustrate the undiminished safety integrity of these fully integrated automation systems, they are described as "integrated, but separate."
The challenge for the user is to assess how these Integrated Safety Systems can still act as a completely independent layer of protection. This webcast will provide the knowledge base necessary for end users to make this assessment.
Asset Performance Management
The ability to improve equipment reliability depends on how well operators are able to identify problem areas with critical assets. This along with performing root cause analysis to understand the underlying issues, rectify recurring losses, and applying proven solutions as broadly as possible across the entire plant will help sustain the improvements over time. Download now.
This Aberdeen Group benchmarking report investigates the ways top-performing companies develop corporate cultures of reliability and leverage investments in advanced performance management capabilities to improve operational performance. Download now.
System Architecture
ABB's automation system innovations have dramatically improved industrial productivity by expanding traditional automated control to provide a common platform for a plant's entire operations, from engineering to process optimization and asset management. Download now.
A central problem in plant operations as well as asset lifecycle management is that you need a way to keep together, manage and have access to information about all different aspects of a great number of plant and process entities (objects). Aspect Object provide the solution to this problem. Download now.
This ARC Advisory Group white paper demonstrates the economic impact and improved business performance to be obtained by integrating the traditional domain of process control with IT technologies and applications. Download now.
As process plants get larger and more complex, automation systems must handle an ever-increasing number of signals. At the same time, the number of electrical consumers increases, making an electrical control system essential. The electrical control system is an automation system in itself providing an interface between the process control and the electrical consumers and actuators. ABB takes responsibility for all these systems and their integration. By letting ABB handle the integration and all the interfaces, customers benefit from faster project execution, reduced re-engineering, higher quality, and higher operational efficiency. Read more.
Evolution
Every manufacturing process has problems or issues of varying severity that reduce productivity, lower product quality and increase operating costs. Every process presents opportunities for improvements with measurable and often impressive results. This is when you can apply the "three steps" to improve your process. Download now.
As manufacturing processes are increasingly
integrated with, and managed by, process automation, a key
part of maintenance is directed towards automation systems. Download now.
As manufacturing processes are increasingly
integrated with, and managed by, process automation, a key
part of maintenance is directed towards automation systems. Download now.
Recent investments in state-of-the-art greenfield plants with state-of-the-art technologies have primarily been directed towards facilities located in the developing world. So, to remain competitive the brownfield manufacturing sites of North America and Europe must significantly improve their return on assets. Learn key strategies for achieving better ROA through the extended use of automation. Download now.
Fieldbus
FOUNDATION Fieldbus High Speed Ethernet (FF HSE) has been a technology available to automation system suppliers since 1999, but very few of these suppliers have provided the full features and functionality offered by this technology to their clients. Download this white paper to learn how ABB's System 800xA utilizes FF HSE more extensively than other control systems. See how utilizing ABB's system, results in a true networked system that allows the process owner to design an overall control infrastructure that reflects both the functional and geographic requirements of the process. Download now to learn more.
Fieldbus integration can provide many benefits to users, yet, despite compatibility standards, there are risks that a system will not work correctly with a given device. A key goal of open vendor independent fieldbus technologies is to integrate devices from multiple manufacturers into automation systems. Theoretically, the implementation of fieldbus standards allows "plug-and-play" connectivity between a device and its automation system. Download now.
Collaborative Production Management
Complex manufacturing processes together with hazardous materials and sophisticated equipment present a unique combination of safety and asset management concerns. Access must be limited to only those employees fully trained and accredited, and physical location tracking of people and assets is key, especially in emergency conditions. Leading process manufacturers are using RFID technology and advanced location sensing algorithms to achieve these goals. Download now.
Integrated safety delivers value while meeting standards
There are two sides to every story and for years, conventional wisdom has said that totally separate control and safety systems were the only way to go. Not so. Today, integrated offerings deliver benefits from reduced training and spare parts to common engineering, asset management and history while still meeting the applicable IEC and ISA standards.
Top Story
Dedicated expert teams provide flawless safety project execution, solutions, consulting
services
ABB reaps benefits of process control and safety integration — without compromising either one.
Key Articles
Configurable safety systems today can be used to realize numerous standard safety functions for drives according to EN 61800-5-2. Download now.
Despite increased dependence on ever more powerful process-control and safety systems, the human aspect remains an integral part of any plant's operation. ABB believes that the safety system of the future is no longer an "add-on," that is designed and supplied separately from the rest of the plant or process, but an integral part of it. Download this white paper to learn more
Modern automation systems provide high levels of interconnectivity, often implemented via commercial IT platforms that are vulnerable to electronic attack. This three-part tutorial explains security objectives, attack types and countermeasures; best practices in protecting against certain types of attacks, and emerging standards for automation system security. Download now
Process control systems have historically been operated in isolation or in a stand-alone fashion. Today, control systems are being connected to enterprise networks to allow business users access to real-time plant data. This integration, however, is not without its risks. Download now
Featured Products
AC 800M HI controller supported bycommon enginering tools, human system interface, historian, audit trail, asset and device management applications, and instrument; therby improving the overall integrity and reliability of BPCS and SIS operations. Read more.
S880 IO HI is a distributed, highly modulized and flexible I/O system, providing easy installation of I/O modules and processing cabling. Read more.
ABB offers a wide range of SIL-rated sensors, valve positioners and actuators from high integrity transmitters with full redundancy designed and certified by TUV against IEC 61508 requirements to standard transmitters with enhanced internal diagnostics to minimize the Probability of Failure on Demand. Read more.
TZID-C200 serves for easy installation in hazardous areas for both the explosion proof housing as well as its capability of being adapted to all common valves with either linear or rotary movement. Read more.
Featured White Papers
Process industries are inherently hazardous, and maintaining safety in processes and operations has become increasingly complex and costly. With both safety and financial concerns being a high priority, those in the process industry sometimes struggle to reconcile them. Download now.
DONG Energy trusts ABBs System 800xA High Integrity to protect critical gas treatment plant such as their Nybro Gas Treatment Plant on the west coast of Jutland, Denmark. DONG Energy uses ABB's System 800xA to handle on a daily basis 16 to 25 million cubic meters of natural gas at this plant. Safety is a priority and setting up a fully automated ESD system increases DONG Energy's plant safety levels. Read the full report and learn how DONG Energy integrates ABB's System 8000xA to process natural gas safely. Download now.
"More" may be "Less" when applied to Safety Systems Architecture. Have the terms DMR, TMR and Quad become irrelevant in your safety system building vocabulary? Download this white paper to learn why categorizing the new generation of systems by its hardward architecture should be avoided. Download now.
SIS logic solver technologies use hardware fault tolerance to improve safety integrity. Higher integrity levels can usually be achieved by implementing identical or diverse redundancy. Diverse redundancy refers to the use of two or more different systems, which are built using different components, algorithms, electronics, design methodology etc. to perform the same task. One benefit of diverse redundancy is the increased capabilities to reduce common mode and systematic failures such as those caused by design flaws. Download this white paper to learn more about the use of diverse redundancy as a defense against hidden dangerous faults. Download now.
Amidst the continued heated discussion on the pros and cons of integrated safety systems market demand — driven by the pursuit of reduced cost, operational excellence and engineering efficiencies — continue to fuel the inevitable integration efforts. This white paper will discuss integrated safety system solutions. Download now.
Videos and Podcasts
To ensure process safety, operators should understand potential events, barriers that protect against the events, and ensure protections are effective throughout the life of the plant. ABB provides methodologies that link hazards analysis with confident development of credible barriers. Watch now.
The System 800xA High Integrity safety system allows the safety system designer to choose the level of integration appropriate for the specific application and control philosophy. From fully segregated, to network integration to fully integrated within the same control hardware, 800xA HI enables users to improve operator effectiveness and promote collaboration through the Power of Integration. Watch now.
Walt Boyes talks with ABB's Dave Huffman about the value, safety and security of state-based control. Don't know what state-based control is? Then you should listen to this three part podcast and find out. Listen now.
Certificates
ABB's AC 800M Controller has recently received two important information security certifications:
Integration of process and power automation delivers results
Electrical integration means integrating process automation and power automation into the same plant control system. This creates a single automation environment that unifies the control of process-related equipment as well as protection, control and monitoring of substation equipment and power transmission and distribution. Integrating the process automation system with the power automation system permits a single strategy in the areas of engineering, operations and maintenance. Whether you generate power or consume it, the economic benefits of electrical integration can run into millions of dollars gained in increased production or saved in reduced operating costs.
Top Stories
Combined process control and safety system cuts costs and boosts efficiency. Read more.
A single system for both Process and Power Automation can reduce investment cost by as much as 20%. Read more.
Key Articles
The introduction of the IEC 61850 standard represents a great step forward in substation automation – and the process in continuing. Subsection IEC 61850-9-2 brings even more value to ABB's field proven substation offering. Download now.
The introduction of the IEC 61850 standard marked an unprecedented revolution for the integration and communication needs of substations. Besides its relevance for new installations, many utilities are seeking to introduce the standard to existing substations as part of retrofit work. Download now.
They implemented ABB's System 800xA to provide a unique and open concept with one IED technology, one library, one control system, and one common IEC 61850 engineering toolset. ABB's solution adds value to the actual assets for the total lifecycle.
Podcasts and Videos
Collaboration between people and systems is necessary to increase engineering efficiency, asset utilization and operator effectiveness. System 800xA was built as an integration platform and has the power to engineer, commission, control and operator control strategies for process, power, electrical and safety in the same redundant reliable system.
Watch now.
Having a control system that provides an integration platform, like System 800xA, is central to having an effective alarm management strategy. Information can then be integrated from multiple sources, providing an overall view of the status of the plant. This consolidated view makes operators more effective and productive.
Watch now.
Operator effectiveness is more than just one simple solution. It is a combination of products, strategies and programs. The four "pillars" of operator effectiveness - integrated system and applications, high performance design, attention to human factors and operator competency - all contribute to a control system environment that provides optimum operator efficiency.
Watch now.
Featured White Papers
ABB Review takes a look at the project in Petrobras' REPAR refinery. This project is a state-of-the-art electrical integration for a refinery, it uses System 800xA and IEC 61850. Download this white paper to learn how ABB accomplished this system integration. Download now.
Communication is more than exchanging data; it means globally understandable information based on syntax and semantic. This is behind IEC 61850, the topic of this issue of ABB Review Special Report.
Download now.
Often referred to as Electrical Integration, Integrated Process and Power Automation is a new system integration architecture and power strategy that addresses the needs of the process and power generation industries. This paper discusses how a single integrated system can increase energy efficiency, improve plant uptime, and lower life cycle costs.
Download now.
The model driven approach of IEC61850 standard is an innovative approach that requires a new way of thinking about substation automation that will result in very significant improvements in both costs and performance of electric power systems. Download this white paper and see how the IEC61850 standard can drive benefits for your business.
Download now.
Application Notes & Success Stories
The proportion of metal found at the Aitik copper mine is low – less than 0.3 percent – it is a highly profitable mine because it is run so efficiently. ABB has contributed to this success by supplying a range of products and systems to power and operate the entire site. Download now.
In addition to a single view of the entire plant, E.On service work can be shifted from troubleshooting to preventative maintenance using System 800xA.Download now.
System 800xA integration capability enabled Arkema to seamlessly integrate TDC3000 data into the 800xA consoles using stepwise evolution, managing both cost and schedule. Download now.
By integrating process and power, using System 800xA and IEC 61850 IED's, Petrobras has achieved increased collaboration and reduced engineering costs. Download now.
Chr. Hansen's engineering group was able to use System 800xA's object technology and libraries to achieve a high level of re-use in their engineering, saving valuable project time.Download now.
The Ormen Lange project will supply 20 percent of Britain''s gas needs for up to 40 years. The project start-up was very successful due to the use of ABB's System 800xA based process simulation. This white paper explains how the second largest gas reserves on the Norwegian continental shelf, The Ormen Lange field, successfully realized this project by using ABB's process simulation systems. Download now.
Dakhalia Sugar's Belkas sugar mill is one of the largest and technologically advanced sugar mills in Egypt. The Egyptian government's longstanding economic goals is to make the country self-sufficient in sugar, therefore, new mills are currently under construction, and older mills are being revamped to increase overall capacity and help reduce the current 50 percent production deficit. Today, 60 percent of the country's sugar mills are equipped with ABB process automation systems. Read this white paper to learn how ABB's system 800xA has improved the sugar mill production processes at Dakhalia Sugar in the Nile Delta. Download now.
In 2008 when the ABB operator system at Cheminova's P1 pesticide plant was changed to System 800xA it had far exceeded the expected lifetime. The transition from the old to the new operator system went without the slightest disruption to production. In this paper, Cheminova's senior engineer Karl Anders Kvist views the future changes of generation that are to take place over the next 2-3 years at the other plants with confidence. Download now.
TVIS is a heat transmission company for the Trekantområdet geographical area of Denmark. It takes care of excess heat from the industries and power plants in the area and redistributes the heat in pipelines to households, public institutions, offices, shops and other facilities in the area. ABB in Denmark has supplied TVIS a SCADA solution based on System 800xA for controlling the district heating network.
Read this white paper to learn how TVIS, in conjunction with ABB's new SCADA solution system, monitor heat transmissions remotely and safely. Download now.
Apart from shear size and automation of the production, tracking production and the ability to trace products is the single most important feature to secure a dominant place in the competitive world market for the Danish slaughterhouse. Danish Crown looks to ABB for new technologies to further improve its bottom line. Production planning, follow-up, quality assurance, documentation and traceability all form an integral part of the factory database. At Danish Crown, an automated factory database system has been developed and implemented using ABB's System 800xA platform. Download now.
DONG Energy trusts ABBs System 800xA High Integrity to protect critical gas treatment plant such as their Nybro Gas Treatment Plant on the west coast of Jutland, Denmark. DONG Energy uses ABB's System 800xA to handle on a daily basis 16 to 25 million cubic meters of natural gas at this plant. Safety is a priority and setting up a fully automated ESD system increases DONG Energy's plant safety levels. Read the full report and learn how DONG Energy integrates ABB's System 8000xA to process natural gas safely. Download now.
Simulator training is becoming an important factor for the pulp and paper industry, as the simulators have become increasingly realistic and provide challenging training for the operators. In all major automation projects today, a simulator is included as an option in the project. In 2006, SCA Östrand pulp mill invested in a simulator for the new recovery boiler and they selected to employ ABB's 800xA Simulator.
Read this white paper to learn how SCA Östrand benefited from their simulator selection and how this system has improved their pulp and paper mill processes. Download now.
Download this success story from Statoil Hydro's Tjeldbergodden plant to learn how they went from being one of the world's largest methanol facilities to also being at the very cutting edge of process control, ergonomics and energy-efficient production with the use of ABB's System 800xA EOW. Read more.
Atanor utilized ABB's System 800xA's functionality to successfully integrate the basic process control system and the safety instrument system. Download this case study to learn how the combined process control and safety system has cut costs and boosts efficiency. Read more.
Download this case study to learn more about Sappi Saiccor's decision to invest in ABB's Advant OCS control system. The investment was preceded by detailed analyzes and project planning measures. An upgrade to newer versions of the installed control system took place five years later; the process is continuing to this day, and recent years have seen a change to the Industrial Extended Automation System 800xA, ABB's new automation platform. Download now.
With an annual production of 500,000 tons of pulp — including 420,000 tons of kraft pulp and 80,000 tons of CTMP pulp — SCA's plant in Östrand, Sweden, is high on the list of Europe's largest pulp mills. Ensuring production stability and efficiency to the highest standards requires a flexible and reliable control system. These values are fundamental to ABB's Industrial System 800xA mode of operation and that is why it was selected to help turn one of Europe's biggest pulp mills into one of the world's most modern. Download now.
By adding System 800xA Extended Automation as part of a recently enhanced control system, Alunorte achieved faster decision making and maxmized production while maintaining product quality. Download now.
Pemex is improving control and safety systems in all its plants and continues to build new facilities. It has support from ABB in all areas of control, safety, instrumentation and power, in each of its subsidiaries. ABB's Analytics, Instrumentation and Services solutions are also utilized by Pemex. Download now.
The installation and commissioning of the plant's automation was running under considerable time pressure. Andras Ujfaludi explains how he managed this challenge. Download now.
Albaugh, St. Joseph, is the only generic glyphosate plant in the U.S. to build upon its track record of success, confident in the cost-effective reliability of its control system. Download now.
RSS
A Shared Vision
The Power of Integration
Industrial energy efficiency: Strategic investments can pay for themselves
The Practical Application of Aspect Object Technology in a Distributed Control System
Collaborative Process Automation Systems
The Business Value Proposition for Automation
Age is No Issue
System 800xA - The Power of Integration
Reliability: A disciplined approach improves asset availability, plant performance and profitability
Ground-up Strategies for Asset Performance Management
Collaborative Process Automation Systems
The Practical Application of Aspect Object Technology in a DCS System
The Business Value Proposition for Automation
Integrated Electrical and Automation Systems
Three Steps to Improving Your Process
Benefits of FF HSE with System 800xA
The Challenge of Device Integration
RFID Helps Track Assets, Manage Safety
Best Practices in Industrial Information System Security
How to Secure Your Control System
AC 800M High Integrity
S800 IO High Integrity
Pressure Transmitter Safety 2600T Series
The New Member of the Exd / ExP Family
Five ways to improve safety and profitability without disrupting operations
System 800xA: Fully Automated ESD System for Major Gas Plant Increases Safety
Why the Architecture of Safety Systems Doesn't Matter
Diverse Redundancy Used in SIS Technology to Achieve Higher Safety Integrity
Optimized Performance Throughout System Lifecycle with Integrated Safety Systems
Refined Integration
A Mine of Efficiency
System 800xA: Electrical Integration at E.ON
System 800xA: Seamless Integration with TDC3000
System 800xA: Integrating Process and Power at Petrobras
System 800xA: Efficient Engineering at Chr. Hansen
System 800xA: Full-Scale Simulation for "Full Gas"
System 800xA Solution for Sugar Mill in Egypt
System 800xA: Change of Generation at Cheminova
For the Sake of the Environment and the Economy: A New SCADA System Based on System 800xA
System 800xA: Structured Data Logger – The Key to Growth for Danish Crown
System 800xA: Fully Automated ESD System for Major Gas Plant Increases Safety
System 800xA: Simulator Gave Östrand Skilled Operators from Day One
Methanol Producer with World-Class Operator Environment
Integrated System Improves Operations
New Application Solutions at Sappi Saiccor with System 800xA
In a league of its own
Alunorte Improves Operational Availability to 99% via System 800xA Extended Automation
Pemex Grows and Improves with 800xA Safety and Control Solutions from ABB
Project Report: Intrinsic-safe Production of Steroids at Gedeon Richter Ltd.
Successful Albaugh, Inc. Relies on ABB's System 800xA