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
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