1. Sustaining an Alarm Management Strategy with ABB’s System 800xA
Presented by Roy Tanner System 800xA Marketing Manager
Title: Sustaining an Alarm Management Strategy with ABB's System 800xA
Abstract: Sustaining an alarm management strategy is not always easy. Come discover how Matrikon's ProcessGuard has been integrated with ABB's System 800xA to help streamline the workflow required to maintain your alarm management program. Featured will be Matrikon's AlarmInsight for System 800xA which gives operations and maintenance personnel easy, contextual access to ProcessGuard and AlarmMOCCA reports via System 800xA operator workplaces. Presenting this information in a single 800xA user environment greatly reduces the time to decision and action and keeping your plant safe as it can be.
Bio: Roy Tanner is the Marketing Manager for ABB's latest state of the art process automation system, System 800xA. Roy is located in Wickliffe, Ohio and has 15 years of experience in the process control arena. As an end user process control engineer, he was responsible for plantwide PLC and DCS systems, continuous improvement programs, and production traceability. Roy has a BSEE from Rochester Institute of Technology.

2. Facts about ABB Headquarters: Zurich, Switzerland
A leading power and automation technology company with strong market positions in its core businesses
Core business organized into 5 divisions; Power Products, Power Systems, Automation Products, Process Automation, and Robotics
Headquarters: Zurich, Switzerland
About 104,000 employees in around 100 countries
Orders in 2005: $23.6 billion
Revenues in 2005: $22.4 billion
Research and Development in 2005: $960 million
Listed on Stockholm, Swiss & New York exchanges; traded on virt-x
What is ABB? ABB is one of the largest power and automation technology companies in the world. ABB is an acronym made up of the first letters from the names of our two parent companies - ASEA AB of Sweden, and BBC Brown Boveri Ltd., of Switzerland. These two companies merged in 1988 to create Asea Brown Boveri, better known as ABB.
Today, ABB employs 102,000 employees in around 100 countries.
We have two core businesses – power and automation technologies – in which we hold market leadership positions. We are number one or number two in nearly every business we compete in.
Company headquarters are in Zurich, Switzerland.
In 2004 we had revenues of $20.7 billion.
Our President and CEO is Fred Kindle, who assumed his role on January 1, 2005.
ABB is a publicly traded company, which means it is owned by shareholders. Shares of ABB stock are listed on exchanges in New York, Stockholm, Frankfurt and London/Zurich.

3. Divisional Structure and Portfolio
Power Products
Sales: $6.4 billion
Power Systems
Sales: $4.0 billion
Automation Products Sales: $5.9 billion
Process Automation Sales: $5.0 billion
Robotics Sales: $1.7 billion
Transformers, high- and medium-voltage switchgear, breakers, automation relays
Substations, FACTS, HVDC, HVDC Light, power plant & network automation
Low-voltage products, drives, motors, power electronics, and instrumentation
Control systems and application-specific automation solutions for process industries
Robots, peripheral devices and modular manufacturing solutions for industry
Market-leading positions in most key product areas
Integrated solutions for grid reliability, productivity and energy efficiency
Robust global value chain to serve established and emerging markets
Extensive global network of value-added channel partners
* Estimated 2005 revenues, Including internal sales to other divisions

4. System 800xA Extended Automation
Reduces time from decision to action
Optimizes plant asset availability and performance
Integrates information for improved visibility
Improves batch consistency, quality, and cycle time
Uses proven solutions based on industry knowledge and experience
Extends installed system capabilities through seamless evolution
Summary of Benefits:
Intuitive Presentation: Desktop displays give managers concise information in familiar office formats. Operator displays provide historical information in the control system environment.
Automated actions: Versatile scheduling options provide automatic triggers for key actions
Flexible report generation and distribution: A wide variety of reporting requirements are supported in familiar formats.
Sophisticated data transformation: User defined data structures and calculations provide powerful, reusable algorithms in addition to external application data support.
Secure historic data storage and access: Fault tolerant and distributed data configurations provide increased data availability. User access is restricted and offline storage is available to protect the integrity of the information.
Integrated administration and configuration: The embedded historian uses inherent system configuration and administration providing for a single information repository for the complete system. This provides single point change management and eliminates duplicate engineering effort.

5. “Traditional” DCS/OCS
Traditional Automation
“Traditional” DCS/OCS
Information
Management
Asset Optimization
S88 Production
Programmable
Logic Control
Advanced Control
Motor Control
Centers
Safety
Distributed Control Systems have been deployed extensively around the world in process and manufacturing industries to achieve productivity improvements by reducing process variability, increasing production availability, and automating tasks. These improvements were gained by focusing primarily on process control. In the 1990’s ABB led the evolution of control system technology by introducing Open Control Systems. OCSs aimed to “open up” the control system environment, making information from the plant floor available to other applications, and allowing OCS systems to interface with other applications principally related to keeping the process running smoothly. It also marked the first major incorporations of “off-the-shelf” technology to replace proprietary versions of Operator Stations, Engineering Stations, and the like. However, the focus was still primarily on the controlling the process.
Today, to deliver additional productivity gains it is necessary to extend the reach of the automation system beyond the world of process control. As mentioned above the traditional DCS / OCS functionality has been the Operations, Engineering, and logic to achieve consistent and predictable Process Control. The Operations functions were focused on the needs of the production operator. Interfaces to applications and devices external to the control system with their own data storage typically were collected and duplicated in the control system database to provide accessibility for reporting and operations needs. This approach was found to be difficult to engineer and maintain. The practice of having information stored in multiple locations brought uncertainty of data integrity as the individual software applications were advanced at asynchronous paces and the customized interfaces between them required frequent maintenance. The increasing deployment of peripheral applications related to productivity improvement such as quality systems, advanced control, production management, information management, and maintenance management resulted in different user interfaces for different types of information sources. More recently the availability of “smart’ field devices has vastly increased the amount of data available to improve productivity in a plant, utility, or mill. However, each device has its own data collection and communication environment, adding to the complexity of the integration task.
Instrumentation
& Drives

6. System 800xA
A single operations, engineering and information management environment for an Extended Automation scope Redefining the Automation System Standard
With the introduction of System 800xA, ABB, redefines the standard for control system functionality by extending the reach of the automation system. From an information access and integration perspective the IndustrialIT system incorporates functionality far beyond process control.
Specifically, the system incorporates Process Control, Production Management, Safety, Discrete Logic and Sequence Control, Advanced Control, Information Management, Smart Instrumentation, Smart Drives and MCCs, Asset Management, and Document Management capabilities in a singular virtual database environment. The Aspect Object technology inherent to IndustrialIT provides the unifying platform base allowing each application to maintain data in its source application, while providing association to a production asset. This allows access to the data directly from it source in the context of the production asset without the need to know where the data is coming from, and without concern about data integrity and concordance. The ability to extend control engineering standards to incorporate and maintain connections to the wealth of IndustrialIT applications we have discussed, and to deploy these standards efficiently across all like instances is one of the unique characteristics of ABB’s solution.
This elegant solution addresses the engineering and maintenance issues of past solutions.
This new IndustrialIT Extended Automation System 800xA provides for a single operations, engineering, and information management environment for the complete scope depicted in this diagram.

7. Industrial IT Technology Partnership
Industrial IT solutions build upon the 800xA extended automation system with integrated devices and 3rd party software applications to deliver Continuous Improvement for our customers.
ABB and 3rd party
Reduced Total Cost of Ownership
Increased Production Output
Improved Safety
Certified Products
The new messaging that you will begin to see over the next few months will focus on the customer value of Industrial IT. The key things to remember our Industrial IT as we move forward is that it is ABB’s commitment to open interconnectivity of automation and power solutions and services, leveraging the ABB portfolio, 3rd party products and the relevant standards.
The deliver of Industrial IT solutions will focus on the following areas of opportunity with our customers (where ROI can actually be measured):
Reduced cost of ownership
Increase production output
Improved safety

8. Industrial IT Technology Partnership
Industrial IT solutions leverage best-in-class products from ABB and partners to deliver value in every solution area.
Infrastructure components
Hirschmann switches
Cisco switches
MOXA switches
OnTime switches
Phoenix switches
Dell PC / Server
HP PC / Server
IBM PC / Server
IBM Blade Server
Intelligent Devices
All devices in the device integration library
>20 HART types
>20 FF types
>12 Profibus types
ABB and other vendors
Fisher
Rosemount
Samson
Westlock
Flowserve
Siemens
Software
800xA Integrated functions
Merriam Device Mgmt System (Calibration)
Real Time Production Intelligence (OEE)
MRO Maximo CMMS
SAP/PM CMMS
IFS CMMS
AES SmartPlant (InTools)
Matrikon ProcessGuard
Hardware
TDC3000 Connect
SafeGuard Connect
PlantGuard Connect
ABB INSUM
Metso Valve Positioner
IIT Training Simulation
Stratus FT Servers
We are currently working to clean up our websites and provide current information on the products that are currently certified (to the old Level 1 or 2). The products listed above are currently IIT enabled. Several are in the process of being updated to SV4 and there are several others in the pipeline (see note above).
Note to Bob: This list may not be exact, so you may get questions about it. Products previously tested will likely be grandfathered, but their certifications will have to be brought up to date during 2005 or they will be removed from the list.
Many products in each category are currently Certified as Industrial IT Enabled against System 800xA.

9. What is alarm management?
It is not a product…
“Work process by which alarms are engineered, monitored, and managed to ensure safe, reliable operations”
Spans multiple departments, requires everyone’s buy in, and part of everyday operational practices
C/O Matrikon Inc.

10. How Are These Objectives Achieved?
Alarm Philosophy
Benchmark &
Assessment
Alarm Rationalization
Implementation &
Execution
Continuous
Improvement
Maintenance
By following a proven process
By using best in class technology to match project requirements
By using standards and good practice guides
Sustaining an alarm management program often presents the biggest challenge
C/O Matrikon Inc.

11. Sustaining the Strategy
Degradation over Time
Alarm Loading / Plant Reliability Indicator
Overloaded
Bad Actors Nuisance Alarms
Can degrade
over time
Bad Actors
Impossible
600
Reactive
Average # Alarms per Hr
Alarm Rationalization 60
Robust
Typical results with DCSs
Rationalization
Stable
With Alarm Hiding X
Dynamic Alarm Handling 6
Predictive
The ABB-Matrikon partnership is focused on
ensuring results are easily sustained! 60
600
6000
Maximum # Alarms per Hr
C/O Matrikon Inc.

12. Continuous Improvement Challenges
Alarm management involves all departments, how can you ensure this is an on-going priority for everyone?
Operations
“ No tools to verify key problems and then take action”
“ I don’t want another screen to look at.”
Engineering
“I follow good change management processes, but I don’t know if the current DCS matches engineered values”
“I need real-time access to CURRENT information on DCS inhibited alarms to verify and approve”
Maintenance / DCS Technicians
“Too much to do already! Are these work orders valid/important?”
“I want a system that is easy to maintain and administer”
Management
“I am losing experienced operators, how can we leverage their experience?”
Personnel are overworked. In order to sustain an alarm strategy, we need to streamline the process!
EEMUA #191 & ISA RP18.2 outline best practices

13. System 800xA and ProcessGuard
Matrikon Process Guard
Comprehensive alarm and event analysis package that simplifies the benchmarking process
Provides a consistent alarm management program throughout the entire lifecycle and enterprise
ABB System 800xA
Extended Automation system built for continuous improvement and risk reduction
Built with Industrial IT technology that consolidates and filters information
IIT Technology Partnership program to connect and utilize best in class offerings
Matrikon AlarmMOCCA
Alarm management of change configuration assistant
Provides a safe environment through improving change management practices
Stores parameters, change logs, difference reporting from actual DCS values
Contains alarm definitions, cause, effect, and recommended action information which can assist operations
Matrikon’s methodology & technology combined with ABB’s 800xA Real-Time Alarm Technology is the first complete alarm management solution!

14. Matrikon AlarmInsight for System 800xA
Industrial IT Vision
Industrial IT is ABB’s commitment to open interconnectivity of Automation and Power solutions and services, leveraging the ABB portfolio, 3rd party products and the relevant standards.
Industrial IT enables ABB to provide three core values to our customers:
Reduced Total Cost of Ownership (TCO)
Increase Production Output
Reduced Risk and Improved Safety
Industrial IT technology enables interoperability of applications:
Direct access to information
Template based connectivity
Single window operator environment
Matrikon AlarmInsight for System 800xA
Matrikon ProcessGuard
ABB System 800xA
AE Messages via Printer port (Serial) Printer port (TCP/IP) OPC AE (SV 5) Text File (Report) ODBC (Info Mgt)

15. Matrikon AlarmInsight
Provides a complete alarm management solution …by providing a certified, pre-tested, integrated system components
Matrikon AlarmInsight Aspect System
Direct, contextual access to ProcessGuard Alarm Analysis and AlarmMOCCA reports to streamline workflows
Direct access to Operator Assistance report giving cause, effect, and recommended action data for operations consistency and decision support.
Easy to implement (no programming needed) to reduce engineering and reduce maintenance.
AECollector able to be loaded on System800xA clients to reduce time to commission.
Combined desktop tools to improve root cause analysis (offered as a service from Matrikon)

16. Functional Structure – AI Report Aspect
Don’t use abnormal situation management…isn’t that owned by ASM’s?? How about critical condition management (ARC)

17. Operator view – AI Report Aspect
Don’t use abnormal situation management…isn’t that owned by ASM’s?? How about critical condition management (ARC)

18. Summary Alarm Management is more than a product
System 800xA has features that help implement and maintain an alarm management strategy such as Alarm Hiding and effective navigation, organization and presentation.
Matrikon’s ProcessGuard has features that
Industrial IT Enabled Matrikon AlarmInsight helps sustain an alarm management strategy