ABB Symphony Plus SD Series HPC800 controller

Symphony Plus

SD Series: HPC800 controller

Symphony® Plus is the new generation of ABB’s widely acclaimed

Symphony family of distributed control systems – the world’s most

widely used DCS in the power generation and water industries.

In all, there are more than 6,500 Symphony DCS installations

in operation all over the world, more than 4,500 of which are in

power and water applications.

No other automation platform has such a long field record

and large installed base in power and water applications

as Symphony. For more than 30 years, ABB has evolved

this family, ensuring that each new generation enhances its

predecessors and is backwardly compatible with them - all in

accordance with ABB’s long-held policy of ‘Evolution without

obsolescence.’

Included in Symphony Plus is a comprehensive suite of

standards-based control hardware and software that meets

the requirements of total plant automation. SD Series

HPC800 represents the newest addition to the S+ Control

family. HPC800 control-based system solutions feature

modular DIN-rail packaging; a flexible, high-performance Fast

Ethernet-based plant network; intelligent electrical and field

device integration; PROFIBUS and HART communication

protocols; integrated turbine control; an efficient, easy-to-use

engineering tool, and a state-of-the-art HMI workplace.

Together, HPC800’s technology enhancements meet the

present and future needs of the power generation and water

industries. HPC800 control-based solutions lower system

installation and maintenance costs through their smaller

footprint, reduced field wiring, simplified and repeatable

engineering, shorter project schedules, tighter and more

reliable process control, and greater visibility of plant

operations to all users of plant data.

Overview

The SD Series HPC800 controller is a high-performance,

high-capacity process controller that is used to support

the plant’s total control requirements, from discrete and

continuous, to batch and advanced control applications.

The HPC800’s controller environment executes demanding

process control applications that are both data and program

intensive. Redundancy options are available at all levels

of control, I/O and communication, resulting in maximum

flexibility and availability.

Along with a range of I/O options, the HPC800 delivers

powerful, versatile and scalable automation solutions for

plant applications of all sizes.

Simultaneously, the HPC800 connects to DIN style I/O

modules and traditional Rack I/O modules. Intelligent I/O

devices such as smart transmitters, actuators, intelligent

electronic devices (IEDs), and third-party PLCs are easily

integrated through industry-standard fieldbuses and

networks. Each device’s resident information can be used

in control strategies and higher-level applications in order to

produce tighter and more reliable process control solutions.

The HPC800 controller uses ABB’s extensive set of

field-proven standard function code algorithms and

S+ Engineering’s graphical design tools to develop its control

strategies. By using the same function code algorithms as

previous generation Harmony and INFI 90 rack controllers,

the HPC800 supports the easy and risk-free re-use of timetested,

field proven control application solutions.

All in all, the HPC800 provides users with the benefits of fast,

accurate and uninterrupted control of their process.

S+ Operations, S+ Engineering and other applications

communicate with HPC800 controllers over the system’s

high-speed, high-throughput and high-security 100 Mbps

Fast Ethernet-based redundant communication Plant

Network (PN800). The network-centric architecture allows

for integration of field devices, process and electrical system

areas, and business enterprise systems in a simple, scalable,

seamless and secure manner.

The HPC800’s functional capabilities are summarized in

figure 2.

Protecting the integrity and confi dentiality of system data

The process and power industries face intensifying cyber

security risks. In order to increase stability, security

and robustness in its solutions, ABB has established an

independent Device Security Assurance Center (DSAC)

where cyber security robustness is tested as part of the

product development process. The DSAC test facility uses

state-of-the-art open source, commercial and proprietary

robustness and vulnerability analysis tools in its certification

testing. All Symphony Plus Ethernet-based devices -

including SD Series products such as the HPC800, and

CI850 - are continually tested at the DSAC center in different

configurations and with an explicit focus on operational

performance. This ensures that all Symphony Plus products

are robust, secure and of the highest quality.

Powerful process controller

The HPC800 is the latest in a long line of field-proven

process controllers. Based on a 256 MHz, 32-bit Freescale

Coldfire processor, the HPC800 controller can be adapted to

a broad spectrum of applications and process requirements.

Configured by S+ Engineering tool, the HPC800 features

an extensive library of more than 150 pre-defined control

algorithms or function codes (figure 3). These functions

provide the ability to easily design complex control strategies

to fi t any control application, including continuous, sequential,

batch and advanced control. In addition to standard function

blocks, the HPC800 supports C programming, batch, and

user defined function codes.

HPC800 controller features include:

− Simultaneous support for SD Series I/O, Harmony Rack

I/O, and S800 I/O subsystems

− Execution of closed loop control of more than 5,000 I/O

in less than 250 msec.

− Downloadable firmware

− Extended user configuration memory (NVRAM) and

runtime memory (RAM)

− Support for 30,000 function blocks

− Flexible and online configuration capability

− Support for up to 8 segment tasks, each segment

supporting execution cycle time down to 1 msec

− Dedicated redundant peer-to-peer controller communication

bus supports update rates less than 100 msec

High reliability and availability

The HPC800 is designed to provide maximum reliability

and availability. With a redundant design at all levels - CPU,

power, internal bus, I/O networks, communication ports and

plant network - HPC800 controller subsystems provide the

highest level of availability. Compliance with international

standards assures the highest level of reliability and quality

needed to meet the most rigorous specifications and

requirements from around the world. Together, they give

users the benefi t of fast, accurate, uninterrupted control of

their process production, resulting in greater production

effi ciency, increased availability and lower maintenance costs.

Ease of use

HPC800 utilizes a DIN-rail form factor, standard 24 VDC

power inputs, and a standard Ethernet network to make

installation simple and flexible. This reduces the limits

on cabinet space, size or layout, and provides a broader

selection of commercial power supplies and network

peripherals, thus lowering both installation and maintenance

costs.

Peer-to-peer controller communications

HPC800’s dedicated bus (CW800) for peer-to-peer controller

communications can achieve update rates of less than

100 msec. It is essential for fast and accurate control,

coordinating between several process segments (ie, between

boiler and turbine), and for when a process point is used

in several subsystems without adding a field transmitter or

cable. The CW800 peer-to-peer communication bus is fully

redundant.

Soft controller reduces commissioning times

For new plant, upgrade, or expansion projects, SD Series

soft controllers can dramatically reduce commissioning and

start-up time and costs by permitting thorough testing and

pre-tuning of control loops prior to its implementation in the

field. The SD Series soft controller uses the same control logic

(ie, function block configuration) as the physical SD Series

controllers. Coupled with virtual communication devices, the

entire SD Series control-based system can be implemented

within one or more PCs which allow for testing results made

in the virtual environment to be directly transferable to the

operating system environment.

Comprehensive I/O support

The HPC800 provides simultaneous support for SD Series

I/O, Harmony Rack I/O and S800 I/O subsystems, and is

capable of providing closed loop control for 5,000 I/O points

in less than 250 msec. This provides great flexibility and a

wide variety of input/output and signal condition capabilities,

which in combination form the optimal automation solution.

Using standard function codes, the S+ Engineering Composer

tool is used to configure and maintain all HPC800 I/O

modules and channels.

Through a redundant I/O network, HN800, each HPC800

controller can communicate with up to 64 SD Series

I/O modules, SD Series PDP800 PROFIBUS modules, or

Harmony Rack RIO22 modules. Each PDP800 can drive

more than 1,500 S800 I/O modules over PROFIBUS DP V2,

while each RIO22 module can drive 64 Harmony Rack I/O

modules. All HPC800 I/O can be configured as either local I/O

or remote I/O or mixed. Remote I/O is communicated via a

fiber optic extension. Sequence of events (SOE) with 1 msec

timestamp resolution is available across the entire system.

In addition to traditional signal-type I/O, the HPC800 provides

for integrated turbine control via a series of turbine controlspecifi

c modules. These are available in either Harmony Rack

form or Symphony Plus DIN-rail form and include:

− Hydraulic Servo Module (HSS and VP800)

− Turbine Protection Module (TPS and TP800)

− Turbine Auto Synchronization Module (TAS and AS800)

− Condition Monitoring Module (CMM and MCM800)

Intelligent HART I/O

HPC800 controllers seamlessly integrate HART field

devices through the HAI805 and HAO805 HART modules.

This provides access to a wide range of intelligent field

devices including transmitters and actuators from ABB

and other vendors. Besides the 4-20 mA primary variable,

all secondary, tertiary and quaternary variables in a

HART device can be accessed by Function Code control

applications in the HPC800 controller. Real time use of this

data is practical because of the modules’ individual HART

modem per channel design. Data can be calculated, used as

part of a control strategy, or for display and alarm purposes

at the S+ Operations console.

HPC800 HART capabilities allow users to take full advantage

of their HART instrumentation investments. Too often smart

devices are under-utilized instruments because of the

limitations of the I/O system to accept the device’s information.

With SD Series HART modules, incorporation of the secondary

variables in control strategies can reduce the overall number

of fi eld devices and I/O channels required. Visibility of HART

diagnostic data at the system level reduces maintenance costs

through the proactive response to degrading performance of

fi eld devices before a failure occurs.

Device integration capability

The HPC800 controller architecture seamlessly integrates

intelligent fi eld devices and protocols using PROFIBUS DP,

HART, Modbus TCP, and IEC 61850. This provides access to a

wide range of intelligent fi eld devices from both ABB and other

third party vendors including transmitters, actuators, motor

control centers (MCC), fl ame scanners, IEDs, etc. Each device’s

resident information can then be used in control strategies and

higher level applications. In addition to producing tighter and

more reliable process control solutions, these solutions lower

installation costs by reducing wiring and system footprint.

Details on SD Series integration devices

The optionally redundant PDP800 PROFIBUS interface

supports:

− PROFIBUS DP V0, V1, V2

− PROFIBUS PA devices through DP/PA linking device

− 1 msec time stamping of devices by PROFIBUS DP V2

− Electric and fiber optic media for PROFIBUS DP link

The CI850 electrical integration interface supports control

and supervision of MCCs, switchgear, transformers,

excitation systems and protective relays via IEC61850. Its

main features are:

− Data modeling according to IEC 61850-7-3 /4

− MMS client functionality according to IEC 61850-7-2

− GOOSE publisher and subscriber functionality

− Capability to send Single and Double Commands

− Capability to send Select Before Operate Commands

− Up to 20 IEDs connected to a single CI850

Accomplished via the controller’s 100 Mbps Ethernet port,

Modbus TCP device integration supports:

− Bi-directional communication up to 4,000 Modbus points

− High availability and fault tolerance in a redundant pair

configuration

− Ability to operate as client, server or server/client

(concurrently) on the Modbus TCP network

− Expanded number of concurrent connections

Field device management

HART and PROFIBUS devices are fully integrated with

Symphony Plus, yielding benefits far beyond reduced

footprint and cable costs. The S+ Engineering tool suite

supports configuration, commissioning and maintenance of

HART and PROFIBUS devices using device type manager

(DTM) technology. For field devices that have conventional

device description files (GSD), a basic PROFIBUS DTM is

available to allow standardized configuration. HART devices

are integrated, configured and parameterized via standard

HART protocol without the need for additional tools by

using a standard HART DTM. The individual DTMs can be

accessed from Composer Field’s multiple data views, such

as the system or location overview and others. Composer

Field includes automatic net calculation and loading

of process items by using the device-specific channel

configuration generated from the DTM.

Based on field proven technology

The HPC800 controller uses ABB’s set of best-in-class

control technologies to build its automation solutions. This

allows end customers and engineering, procurement and

construction (EPC) contractors alike to effectively re-use their

extensive library of ABB field-proven and time tested control

solutions with these latest control products.

Specifically, HPC800 solutions:

− Use the extensive set of field-proven INFI 90 function code

algorithms as previous generation controllers

− Use traditional INFI-Net exception reporting over

redundant 100 Mbps Fast-Ethernet (PN800)

− Extend current Composer graphical design engineering

tools with device management capabilities

Further, Symphony Plus Rack and DIN control networks,

INFI-Net and PN800 respectively, can be connected via a

self-configuring INFI-Net to Ethernet bridge (IEB800) module.

Use of this bridge makes resident data on either network

available for use in control applications or display in the other

system