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IEEE PES Meeting Marc L. Hunter

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1 IEEE PES Meeting Marc L. Hunter
Foxboro A2 Automation Platform Business Manager North American Marc L. Hunter

2 Agenda Discussion of DCS, PLC, SCADA, and Hybrid control systems
Markets served by various technologies Hybrid control system advantages in Water and Waste Water Technology Future of Invensys – setting the pace for automation industry Homeland Security

3 Distributed Control “A design approach in which factory or machine control is divided into several sub-systems, each managed independently by a unique programmable controller or other control system, yet all interconnected to form a single entity. Individual subsystems may be interconnected via communications networks.” Patrick-Turner Industrial Automation Dictionary, 1996

4 Distributed Control System Advantages
Fault tolerant controllers Redundant input/output card capabilities Redundant communications Advanced control configuration Integrated human machine interface Industry domain expertise Program control security

5 Programmable Controller
“A solid state industrial control device, member of the computer family, designed specifically to be programmed to perform relay logic functions, timing, counting, arithmetic, and data manipulation, all for the purpose of implementing control over industrial machines and processes. The programmable controller consists of a central processor, memory system, input/output system, and power supply, all of which are designed to operate in harsh industrial environments.” Patrick-Turner Industrial Automation Dictionary, 1996

6 Programmable Logic Controller Advantages
Easy to use and install Distribution network – local electrical supply house Inexpensive Electrician can diagnose and upgrade ADEQUACY $ per point for DCS versus $ 275 per point for PLC = budgetary figures from KBR, Fluor Daniel, and Bechtel

7 SCADA Supervisory Control – “A control scheme whereby a computer or controller monitors and intermittently downloads programs, sets sub-goals, or adjusts control parameters of a lower level automatic controller.” Data Acquisition – “The process of collecting data from the system through some manual or automatic means for the purpose of producing printed reports for operating, supervisory, maintenance, or accounting disciplines.” Patrick-Turner Industrial Automation Dictionary, 1996

8 SCADA Advantages Integrated package – communications and control
Tailored to specific application Niche market domain expertise Key attributes within communications Economical

9 Hybrid Control System “A control system that takes the advantages of all different control system hierarchies and feature sets to combine into a new revolutionary approach for solving control and integration issues in today’s competitive manufacturing and processing industries.” Marc L. Hunter; MBA, MS Automation “The power and performance of a DCS at the price and ease of use of a PLC” Invensys Foxboro

10 Hybrid Control System Advantages
All advantages of DCS, PLC, and SCADA rolled into one Redundant communications and controllers Advanced control configuration – IEC 61131 Integrated human machine interface Industry domain expertise Program control security Easy to use and install Inexpensive Electrician can diagnose and upgrade Designed as process controller not relay replacement

11 DCS - PLC - PC/PLC Traditional Report Card
Powerful Advantages of PLCs include: Excellent logic handling capabilities; operators in US like ladder logic! Tolerate rough environments [but typically not corrosive atmospheres] High level of flexibility; generally compact & save space Main drawbacks of PLCs include: Non-deterministic - no ability to predict response time, disastrous for PID control! Only if real-time interrupt is available (& used for PIDs) [only in A-B PLC-5s?] Limited continuous control capabilities…esp. multiloop strategies & optimizing Lack of batch software packages Use of HMIs from other vendors limit capabilities (need more than a pretty face), generally need separate configuration “box” from operators Lack of process expertise usually means independent integrator must install adding to engineering costs.

12 Foxboro A2 Hybrid Automation System Traditional PLC Offering
Where do we fit? Total I/O Quantity Bit Logic Solving Hybrid Continuous Algorithm DCS Process Industry Foxboro A2 Hybrid Automation System System Complexity Traditional PLC Offering Discrete Industry

13 Automation Architecture Migration
Process Industries Hybrid Discrete ABB Emerson Honeywell Invensys Siemens Yokogawa Mitsubishi Omron Rockwell Schneider Siemens Petrochemical Refining Power Pulp & Paper Pharmaceutical Fine Chemical Food & Beverage Consumer Packaged Goods Automotive Aerospace Machining This illustration shows the view by ARC Advisory Group of how the PLC vendors and the DCS vendors are migrating into the functions of the different industries. They first have moved into what they define as the hybrid industries, then they reach into the other world beyond their traditional markets. In theory, all these systems are microprocessor-based, so they should be able to do any job. You can also go to a formal dance in a pick-up truck, and carry supplies from the lumber yard in your high performance sports car. Like buying an automobile, you will want to look carefully at what your plant really needs, and not get carried away with only the “gee-whiz.” With Permission From ARC Advisory Group Strategies – June, 2001

14 Traditional PLC Vendor Supply Model
End User Buys from: …AND …Indirectly From Suppliers: Component Manufacturer(s) Implementer Distributor Software Drive PLC Motion Sensor OEM System Integrator Engineering Contractor Distributors Value Added Resellers Manufacturers Representatives There are also traditional Supply Models from each world… that of the manufacturing world emerged for the PLC. Often the PLC supplier provided volume of hardware boxes with identical software. They were not in the application business. For a very long time, the PLC world was in the automotive industry, accounting for about 70% of the use. This of course is changing like everything else, but the prior influence is still quite strong. You also see many PLC suppliers now providing their own specifically focused HMIs as well, to reduce the “shopping cart” effect of so many independent components. HMI Manufacturer

15 Traditional DCS Vendor Supply Model
End User Buys from: …OR …Directly From Supplier: DCS Manufacturer Capabilities System design IT integration Process optimization Performance guarantees Single Source Supply Global support System Integrator Engineering Contractor Services Project Management Engineering Field services Technical call in Consulting Here we see the traditional Supply Model of the DCSs vendor. Keep in mind, this came about by the “proprietary-ness” of the design. DCS suppliers came from a world of single loop controllers, which by their very architecture had the operator interface (HMI) designed directly into the controller, and out of necessity was one in the same. The pointer on the faceplate was driven directly from the controller mechanism. In contrast, the PLC was a discrete box where the only operator action was essentially turning it on or off. Platform Software Control I/O

16 Combined Systems vs Hybrid Systems
PLC and HMI System Hybrid Control System Components function/scope not coordinated Components function/scope coordinated Function extensions in components for system performance System functions are included in individual components Frequently from various suppliers From a single source Integration work necessary Integrated overall system Product competence Application/system competence Individual product responsibility System responsibility Individually optimized components Optimally coordinated system Innovation cycles not coordinated Innovations coordinated Here what we are really comparing are the differences between component-based systems to be assembled by the user or the integrator. In these next views, keep in mind that both PLC and DCS suppliers are beginning to provide Hybrid capabilities. We are comparing those with the old traditional PLC with another supplier’s PC added for the operator interface. The hybrid alternative provides the components designed to automatically fit together… pre-integrated to a very large extent. Their functions an scope are designed to be coordinated, their design upgrades are designed to be coordinated as well. In addition, the Hybrid supplier generally provides application-specific features that are coordinated among the various components that work in unison. This augments the overall integration and responsibility of the system. As new innovations emerge with hybrid systems, they are usually designed to fit in to the design program of the other components of that same system so they compliment each other. In a combination of components, someone must usually engineer the separate parts to fit into any new design of any one of the separate components.

17 Implementation effort
PLC and HMI System Hybrid Control System Alarms / messages Diagnosis Redundancy Documentation Access rights Customer Support Uniformity not ensured Additional effort by user Uniform functions System performance without additional effort Certainly the implementation effort is far easier in hybrid systems. Hybrid Systems more easily provide essential continuity of not just alarm management and screen hierarchies, but Diagnostics Redundancies Access rights of other devices as well as people And customer support among the diverse devices All contribute to system performance without additional effort of engineering the integration High integration effort

18 Economical over entire life cycle (total cost of ownership )
Combined System from various manufacturers Hybrid process control system Expansion costs Homogeneous configuring landscape Up-to-date documentation Scalable system hardware Expansion Expansion Maintenance costs Integrated service concept Adapted versions Maintenance Maintenance Engineering and startup System-wide configuring tools Integration support Engineering Engineering System costs System hardware System software HW/SW components Economical over entire life cycle (total cost of ownership) Total cost of ownership is more than a buzzword with hybrid system compared with systems of integrated components from various manufacturers. Today, even system costs are probably not a premium with hybrid systems as they were when comparing DCSs over PLCs. Then as we saw earlier, engineering the system into a specific plant requirement is less. Uniformity means that maintenance is more consistent, not just because of the system-wide diagnostics of how the components perform together, but how the troubleshooting and physical techniques are achieved. Training applies to more of the components, so less training is needed. The uniformity of the system-wide diagnostics generally reduces the ambiguity, so locating problems is much faster and more effective. The uniformity usually means that scaling up is easier. The uniformity usually means that technology upgrades are more practical without wholesale replacements in the future. HW/SW components Investment in system performance is more than compensated through savings in engineering!

19 Visualize Analyze Optimize ArchestrA Framework Current status Monitor
Problems Find opportunities Office Platform Story – plant of the future to operate like microsoft desktop Optimize Spread best practices Adjust process & procedures

20 Sustainable Integration
ArchestrA is an innovative technology that is focused on collaboration in the design, use and maintenance of plant automation ArchestrA uniquely normalizes diverse sources of data into a secure, object-based environment. ArchestrA has a library of over 1,000 programmable plant floor devices ArchestrA uniquely enables adaptive security for central or remote control rooms Invensys Honeywell Siemens Rockwell Emerson Yokogawa Schneider ABB Palletizing Bottling Labeling Inventory Filling Processing Batching Utilities Today’s Islands of Automation Collaboration Intelligent Equipment

21 Homeland Security for Drinking Water Supplies
Three Areas Increased physical security surrounding water supply systems Redundancy design in the system Source water protection and monitoring

22 “Homeland Security for Drinking Water Supplies”
The most expedient and potentially less costly actions for protecting a water supply system consist of installing or enhancing a physical security system, including fences, exterior and interior sensors, alarm assessment and communication and entry control. The risk of cyber threat can be reduced by increasing security in the Supervisory Control and Data Acquisition (SCADA) System used for utility monitoring and operation and remote communication. SCADA security can be tightened by either hardware or software enhancements by IT professionals. Marcia Greenblatt, Ph.D., Jack Donohue, and Ken Wagner Ph.D. Courtesy of ENSR International Translation: Control system design consideration other than adequacy of meeting control needs.

23 “Homeland Security for Drinking Water Supplies”
Source water protection and early warning monitoring systems could alert operators of any change in water quality in sufficient time to prevent contamination and disruption of the public water supply. Early water monitoring requires a long-term baseline of water quality data to understand typical parameter ranges. When observed water quality parameters are outside expected values, warning signals can be transmitted, increased sampling and testing can be conducted, and the system operation adjusted appropriately. In addition to a well designed monitoring system, an inventory of system hydrology (including reservoir residence times, dilution rates, flow-stage relationships, etc.) will allow for rapid assessment and decision making in the event of contamination. Marcia Greenblatt, Ph.D., Jack Donohue, and Ken Wagner Ph.D. Courtesy of ENSR International Translation: You cannot control what you cannot measure!! SQL focal discussion point

24 Simple solutions for security
Prepare (or update) an emergency response plan. Make sure all employees help to create it and receive training on the plan Post updates emergency 24-hour numbers at your facilities in highly visible areas (pump house door, vehicles, office) and give them to key personnel and local response officials Get to know your local police and ask them to add your facilities to their routine rounds. Practice emergency response and public health officials Fence and lock your drinking water facilities and vulnerable areas (e.g. wellhead, hydrants, manholes, pump house, and storage tanks) Lock all entry gates and doors and set alarms to indicate illegal entry. Do not leave keys in equipment or vehicles at any time Install good lighting around your pump house, treatment facility and parking lot Identify existing and alternate water supplies and maximize use of back flow prevention devices and interconnections Use your Source Water Assessment information to work with any businesses and homeowners that are listed as potential sources of contamination and lesson their threat to your sources Lock monitoring wells to prevent vandals or terrorists from pouring contaminants directly into ground water near your source. Prevent pouring or siphoning contaminants through vent pipes by moving them inside the pump house or treatment plants, or if that isn't possible, fencing or screening them In case of an emergency, first call "911", then follow your emergency response plan From: EPA New England Office

25 Foxboro A2 answers “Call to Duty”
Control System Security – 21 CFR Part 11 compliance Control Variables Secured Network Secured Historical Records Secured Physical Security Limit switches on doors, fences, and gates integrated into control system – industry domain expertise Live video feeds from critical points and integrated into control system Accurate Control system data locked into secured database

26 Invensys Newsletter Link
AWWA Interim Voluntary Security Guidance for Wastewater/Stormwater Utilities – Chapter 5 Cyber Security Pretreatment and Effluent EPA Guidelines Case Studies

27 Conclusion Discussion of DCS, PLC, SCADA, and Hybrid control systems
Definitions and advantages Markets served by various technologies Technologies to appropriate industries Hybrid control system advantages in Water and Waste Water Technological advantages of all rolled into one Technology Future of Invensys – setting the pace for automation industry AchestrA – all elements of plant working in concert Homeland Security Actions and control system complements

28 Questions and Comments


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