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Remote Diagnostic Services Portfolio

Remote Diagnostic Services Portfolio. Process Control Systems Quality Control Systems Analytics PID Control Loops Medium Voltage Drives Low Voltage Drive Systems Rotating Machines. Remote Diagnostic Services - Introduction. RDS General Information. Remote Services Overview

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Remote Diagnostic Services Portfolio

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  1. Remote Diagnostic Services Portfolio Process Control Systems Quality Control Systems Analytics PID Control Loops Medium Voltage Drives Low Voltage Drive Systems Rotating Machines

  2. Remote Diagnostic Services - Introduction RDS General Information • Remote Services Overview • Remote Diagnostic Services (RDS) • RDS Support Process • RDS Connectivity Solution • Asset Types Supported

  3. Remote Diagnostic Services RDS General Information Designed to help customers to… • maximize equipment productivity • minimize maintenance costs • optimize process throughput SupportLine Remote Diagnostics • Availability (24x7) • Speedy Response • Proactive Service

  4. Remote Diagnostic Services RDS General Information RDS Programs: • Troubleshooting – On-demand connectivity to assist in diagnosing a specific system event or failure via a secure high-speed remote connection. • Periodic Maintenance – asset monitoring and collection of asset parameters for detection of variances from benchmark performance. Includes detailed quarterly health check reports. • Continuous Monitoring – Real-time uninterrupted monitoring of critical asset conditions which are compared to pre-defined thresholds. Alarms auto generate an entry in ABB’s case management system for immediate resolution. 1-800-HELP-365

  5. RDS - Periodic Maintenance RDS General Information Quarterly health checks reports include: • Asset status overview • Event summary for the period • Software / firmware revision analysis • Recommended preventive actions based on changes in operating parameters • Recommended corrective maintenance based on event and error reports

  6. RDS - Periodic Maintenance RDS General Information Quarterly health checks reports include: • Asset status overview • Event summary for the period • Software / firmware revision analysis • Recommended preventive actions based on changes in operating parameters • Recommended corrective maintenance based on event and error reports

  7. RDS - Continuous Monitoring RDS General Information • Event based monitoring of asset performance • Detection of significant events and variances from benchmark • Notification based on business rules: • Low-level alarms: Local alert on maintenance console • Medium-level alarms: E-mail ABB Support Center • High-level alarms: Send alert to ABB SupportLine text pager • ABB responds to alerts or customer call-ins: • Contact customer • Initiate remote connection • Diagnose event data • Create incident report • All incidents are tracked in ABB’s SupportLine case-tracking system for site history.

  8. Remote Diagnostic Services RDS General Information Features • Around-the-clock access and technical support • Remote access-on-demand • Secure broadband connection • E-mail/Pager Alerts • Predictive and preventative Maintenance • Access to a wider range of ABB’s technical expertise Benefits • Reduced overall maintenance costs • Optimized asset performance • Real-time access and support • Fast and automated information retrieval • Condition reporting enhancements Optimize Asset Availability and Performance

  9. RDS Enhances Site Maintenance/Service RDS General Information Enhance Site Based Service • Remote expert support for in-house troubleshooting efforts • Continuous monitoring of critical assets • Pre-notification of developing adverse conditions • More efficient response to unplanned system events • Direct access to alarms, events, and error logs • Recommendations for corrective and preventive maintenance • Support for managing system upgrade and migration planning Site Service Enhancements

  10. RDS Global Scope of Coverage RDS General Information Northern Europe and Asia Action Center Regions Americas Europe, Middle/Near East, Africa

  11. RDS Connectivity Solution RDS General Information • Software/Hardware Required • Firewalls – Described • Connection – Topology • Security Measures • SSL Defined • Advantages over Dial-Up or VPN

  12. RDS Node – Software/Hardware Requirements RDS General Information Trouble Shooting and Periodic Maintenance • Customer Provides access to workplace machine • Operating System - Windows 2000/XP Pro • Internet Access Continuous Monitoring • ABB Provides RDS Node (AO Workplace) • LAN Connection for Internet Access • Connection to OCS and Space for RDS Node

  13. RDS – Secure Connections RDS General Information Blocked: Connection initiated by inbound attempts. Allowed: Connection initiated by RDS Service Agent Typical firewall configurations: • Allow outbound HTTP and HTTPS connections • Web browsing relies on typical rules • Blocks inbound connections to most computers RDS Connectivity: • Secure tunneling technology (ABB’s RDS Service Agent) preserves and extends security at customer locations • Bi-directional communications • Does not compromise customer firewalls • No VPN to configure and maintain • Supports TCP/IP sockets, serial, and Telnet connectivity

  14. RDS – Secure Connection Topology RDS General Information

  15. Security Measures RDS General Information Remote Diagnostic Services provide the following measures to insure data security: • Utilize customer standard firewalls (or custom firewalls for direct connections) to protect devices from public access • Enables customer to set level of access to specific devices and information • Logs all remote sessions • Allows customer to designate which information can be transmitted out of facility • Encrypts data using Secure Socket Layer (SSL) protocol to prevent interception Security ABB - 3BUS 004 417

  16. SSL Defined RDS General Information What is Secure Socket Layer (SSL)? SSL is encryption technology that addresses threats to information sent over the Internet: • Data seen by an unauthorized third party. • Third party alteration of your data. • Third party impersonation of the intended recipient. Secure Data SSL encryption technology assures the confidentiality and integrity of any information sent over the internet. A message is coded so that it cannot be decrypted by anyone but the intended recipient. If someone tries to alter an encrypted message, it will not decode correctly and the proper recipient of the message will be alerted to the fact that the message has been tampered with.

  17. Advantages Over VPN and Dial-Up RDS General Information Advantages over VPN • No need for additional VPN hardware and software on either side. ABB and customer can make use of their existing network infrastructure. • Easy to install RDS Service Agent on RDS Node at customer’s site. Advantages over Dial-Up • Dedicated phone line for the device is not required • Off the LAN connections bypass the protection of corporate IT • Slower than high-speed Internet, can slow down interactive sessions. • Setup is time consuming for non-existing dial-up lines • Easier to Install RDS Node • Easier to make a remote connection.

  18. Remote Diagnostic Service Applications RDS General Information Click the links below for additional information regarding the following asset types: Process Control Systems Quality Control Systems Analytics PID Control Loops Medium Voltage Drives Low Voltage Drive Systems Rotating Machines Maximum Asset Availability and Performance

  19. ABB logo X ? Select Asset Type End Presentation

  20. Process Control Systems RDS for Process Control Systems Remote Diagnostic Services for Process Control Systems Systems supported: • 800xA • Harmony • MOD • Master • System Six Maximum Asset Availability and Performance

  21. RDS Continuous Monitoring RDS for Process Control Systems RDS-Continuous Monitoring provides: • Instant notifications through alarming and messaging • Quicker diagnostics from more readily available information • Automatic case creation and notification of ABB Technical Support for critical asset conditions • Asset Firmware/Hardware version management • Loop topology presentation • Key performance indicator trending & predictive maintenance • Historical data collection • Remote visibility for system status and performance information

  22. The following Conditions are Monitored RDS for Process Control Systems Communication System • Node Performance Statistics • NIS Event and Error Counters • Loop and Node throughput • Loop topology Module Status • Module alarm event notification • Power Supply Status • CPU and Memory Utilization Operator Console Health • Disk space, CPU and Memory Utilization • Verify critical processes are running

  23. Firmware Management Is your system up to date? RDS for Process Control Systems

  24. Event and Error Counter Trending RDS for Process Control Systems Will these error rates go away on their own?

  25. Node Performance Trending How much longer do you want to run with the high possibility of data loss? RDS for Process Control Systems

  26. Alarm List – Real Time Notification RDS for Process Control Systems For example, learn about module failures right away.

  27. RDS for Process Control Systems Value Assessment Troubleshooting Periodic Maintenance Continuous Monitoring * Costs will vary depending on system configuration. Does not include one-time installation fee.

  28. ABB logo X ? Select Asset Type End Presentation

  29. Drives & Drive Systems RDS for Drives & Drive Systems Remote Diagnostic Services for Drives & Drive Systems Drives Supported Low Voltage Drive Systems • ACV700 • ACS600 • ACS800 • DCV700 • DCS600 Medium Voltage Drives • ACS1000 • ACS5000 • ACS6000

  30. Drive Software Tools RDS for Drives & Drive Systems RDS Monitoring provides: • Remote Access to existing ABB DriveWare enables RDS Troubleshooting and Periodic Maintenance

  31. System Drives – Value Assessment RDS for Drives & Drive Systems • Troubleshooting • Periodic Maintenance * Costs will vary depending on system configuration. Does not include one-time installation fee.

  32. ABB logo X ? Select Asset Type End Presentation

  33. Quality Control Systems RDS for Quality Control Systems Remote Diagnostic Services for Quality Control Systems QCS Assets Supported: • Frames & Sensors • Supervisory Control • Smart Advisor Camera System • Ulma Web Imaging Maximum Asset Availability and Performance

  34. Frames & Sensors Supported RDS for Quality Control Systems Sensors • Ash • Basis Weight • Caliper Color Gloss • Moisture • IR Sensors • OptiPak • Reflection IR • IR Coat Weight** • Fiber Orientation** • Temperature** • Microwave** • X-ray Coat Weight** • **Continuous Monitoring availability limited Frames • Smart Platform:1200 • Smart Platform:700* • Smart U-Frame* • Reflection Smart Platform* *SP 360.0 or later with MPRC board 086444-004 or later

  35. Conditions Monitored RDS for Quality Control Systems RDS Monitoring provides: • Record and compare actual scanner & sensor parameters to benchmark • Voltages • Temperatures • Internal check samples • Software revision levels • Sensor setup parameters • Sensor standardize variables • Sensor measurement variables • Scanner setup variables

  36. Frame & Sensor Conditions Monitored RDS for Quality Control Systems Sensor Measurement Health • Standardize predictive checks • Standardize reactive checks Excel Based Sensor Reports Reports are collected and analyzed but no AMs are tripped. • Standardize • Calibrate Sample • Sample Check Sensor Hardware Health • Basis Weight • Number of shutter movements • Source decay monitoring • Sensor Alarms Scanner Health • Predictive Flex Cable Failure • Excessive scanner offsheet time • Number of Scans • Flex Cable warning flag • Frame Temperature • Frame blower plugging • Monitor both IR head water flow indicators

  37. Troubleshooting Frames & Sensors Value Assessment RDS for Quality Control Systems • Periodic Maintenance • Continuous Monitoring * Costs will vary depending on system configuration. Does not include one-time installation fee.

  38. ABB logo X ? Select Asset Type End Presentation

  39. Analytics RDS for Analytics Remote Diagnostic Services for Analytical Equipment Assets Supported: • Continuous Gas Analyzers (CGA) • Chromatograph (GC) • Fourier Transform Infra-Red (FTIR)

  40. Analytics RDS for Analytics RDS Monitoring provides: Remote Access to existing ABB Analytics Software to offer RDS • Troubleshooting • Periodic Maintenance

  41. ABB logo X ? Select Asset Type End Presentation

  42. PID Loop Performance Monitoring RDS for PID Control Loops Remote Diagnostic Services for PID Process Control Loops Performance Monitoring • ABB Control Systems • Emerson Control Systems • Honeywell Control Systems • Siemens Control Systems • Invensys Control Systems • Others that support OPC communications

  43. Loop Condition Evaluations RDS for PID Control Loops Loop Conditions • Tuning Problem • Loop or Setpoint Oscillations • External Disturbances • Non-Linearity • Unreliable Data • Harris Index Acceptability • Setpoint Crossings • Variability • Auto/Manual • Cascade Tracking • Response Speed • Loop Performance (Summary Condition)

  44. LPM Features – Data Collection RDS for PID Control Loops RDS Monitoring provides: • Configure database by loops • Simultaneous data collection for multiple loops • OPC connectivity • Direct connection for Infi 90 • Data collection stored as object on navigation tree for future retrieval More direct connections in next release

  45. LPM Features - Tuning RDS for PID Control Loops • Tuning • 5 Tuning methods available (manual, lambda, Dominant pole placement and IMC for both PI and PID) • Simulation against both disturbances and set-point changes • Feedforward control tuning • Graphical and numerical tuning evaluation tools (both in time and frequency domain) • Tuning results saved in Logs for future reference and history

  46. Loop Performance Audits RDS for PID Control Loops Performance Audits • Is the loop tuning too sluggish? • Is there excessive noise on the PV signal? • Is the overall statistical behavior of the loop good? • Does the loop show signs of persistent oscillation? • Are there problems with the valve? • Is the tuning causing excessive valve wear? • Does the valve show signs of leakage when shut (flow loops)? • Is the actuator saturated for significant periods of time? • Is the setpoint oscillating (cascade loops)? • Does the PV track the SP (cascade loops)? • Is the overall control performance good?

  47. Periodic Maintenance - Reports RDS for PID Control Loops Audit Reports • Loops are grouped both by Area and by Category • Up to 41 different KPI’s reported • Quarterly reports provided • Overall performance • Poorly performing loops • Corrective action recommendations

  48. PID Control Loops – Value Assessment RDS for PID Control Loops • Troubleshooting • Periodic Maintenance • Continuous Monitoring * Costs will vary depending on # of loops. Does not include one-time installation fee.

  49. ABB logo X ? Select Asset Type End Presentation

  50. Rotating Machines RDS for Rotating Machines Remote Diagnostic Services for Rotating Machines • Electric Motors • Pumps • Fans and Blowers • Compressors • Generators • Gearboxes

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