ieee pes meeting marc l. hunter foxboro a 2 automation platform business manager north american
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IEEE PES MeetingMarc L. HunterFoxboro A2 Automation Platform Business ManagerNorth American
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
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
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
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
Programmable Logic Controller Advantages
Easy to use and install Distribution network – local electrical supply house Inexpensive Electrician can diagnose and upgrade ADEQUACY
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
SCADA Advantages
Integrated package – communications and control Tailored to specific application Niche market domain expertise Key attributes within communications Economical
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
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
DCS - PLC - PC/PLC Traditional Report Card
WARNING! GENERALIZATIONS PRESENT DCS PLC HybridControl Capabilities
Process I/O A A BMultivariable Regulatory Control A C BComplex Interlocking C A ASequencing B D ARecipe Handling A D ABatch Process Control B D A
User Interface:Ease of Configuration (links & displays) A C AEase of Operator Use A D AEase of Creating Custom Displays A C A
Cost:Hardware C A AInstallation A C AApplication Programming A B A
Additional Considerations:Ease of Expansion (interactive functions) A D AFlexibility A D ARedundancy A C BReliability B A AHardware Maintainability B A ASoftware Maintainability B C A
Where do we fit?
Bit Logic Solving Hybrid Continuous Algorithm
Pro
cess
Ind
ustr
yD
iscre
te
Ind
ustr
y
Foxboro A2 Hybrid Automati
on System
DCS
Traditional PLC
Offering
Syste
m C
om
ple
xit
yTotal I/O Quantity
Automation Architecture Migration
ProcessIndustries
HybridIndustries
DiscreteIndustries
AutomotiveAerospaceMachining
PharmaceuticalFine Chemical
Food & BeverageConsumer
Packaged Goods
PetrochemicalRefiningPower
Pulp & Paper
ABB Emerson
HoneywellInvensysSiemens
Yokogawa
MitsubishiOmron
RockwellSchneiderSiemens
With Permission From ARC Advisory Group Strategies – June, 2001
HMI HMI ManufacturerManufacturer
Traditional PLC Vendor Supply Model
SoftwareDrivePLC
MotionSensor
OEMSystem IntegratorEngineering Contractor
Implementer Distributor
End UserBuys from: …AND …Indirectly From Suppliers:
Component Manufacturer(s)
DistributorsValue Added ResellersManufacturers Representatives
System Integrator
EngineeringContractor
Traditional DCS Vendor Supply Model
End User
Capabilities System design IT integration Process
optimization Performance
guarantees Single Source
Supply Global support
DCS DCS ManufacturerManufacturer
Buys from: …OR …Directly From Supplier:
Services Project
Management Engineering Field services Technical call
in Consulting
Platform
SoftwareControl
I/O
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
• Uniformity not ensured
• Additional effort by user
High integration effort
• Uniform functions• System
performance without additional effort
Alarms / messagesDiagnosis
RedundancyDocumentationAccess rights
Customer Support
Implementation effort
PLC and HMI System Hybrid Control System
System costs System hardware System software
Engineering and startup System-wide configuring tools Integration support
Maintenance costs Integrated service concept Adapted versions
Expansion costs Homogeneous configuring landscape Up-to-date documentation Scalable system hardware
Engineering
Maintenance
Expansion
HW/SW components
Hybrid process control system
Combined System from various manufacturers
Investment in system performance is more than compensated through savings in engineering!
Economical over entire life cycle (total cost of ownership )
Engineering
Maintenance
Expansion
HW/SW components
ArchestrA Framework
Visualize• Current
status• Monitor
Analyze• Problems• Find
opportunities
Optimize• Spread best practices• Adjust process & procedures
Sustainable Integration
Today’s Islands of A
utomation
Batc
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Fillin
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Lab
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Palleti
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Bott
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Inven
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ockw
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Yokog
aw
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AB
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neid
er
Utilities
IntelligentEquipment
Processing
Inventory
Collaboration
• 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
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
“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.
“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!!
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
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
Invensys Newsletter Link
http://www.foxboro-newsletters.com/Insights0405int.htm– AWWA Interim Voluntary Security Guidance for
Wastewater/Stormwater Utilities – Chapter 5 Cyber Security
– Pretreatment and Effluent EPA Guidelines– Case Studies
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
Questions and Comments
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