improving and scaling scada systems: is wincc oa right for me?

Unrestricted © Siemens Industry, Inc. 2015 All rights reserved.

Siemens Industry Oil and Gas ConferenceApril 22nd, 2015


Kristie SheaImproving and Scaling SCADA Systems:Is WinCC OA Right for Me?

Agenda

Introduction

WinCC Open Architecture (OA) Overview

Case Study Presentation Distributed System

Project Example Applying solution to

O&G

Questions

Presenter InfoKristie Shea

Project Manager

Siemens Certified Professional

Certified WinCC 7 Engineer

Certified WinCC OA Engineer

M.S. in Mechanical Engineering

University of Illinois in Urbana-Champaign

B.S. in Mathematics (Applied)

University of Illinois in Urbana-Champaign

With DMC since 2006

DMC Company Profile

Industries Served:

Automotive

Chemical and Food

Processing

Electronics/Semicondu

ctor

Hydraulics

Laboratory Testing

Machine Tool

Material Handling

Metal Converting

Packaging

Pharmaceutical

Printing & Textiles

Oil & Gas

Established in 1996, offices in Chicago, Boston, NY, Denver, Houston & customers

throughout the world

employees & growing

70+

Areas of Expertise

MANUFACTURINGAUTOMATION & INTELLIGENCE

PLC Programming

Motion Control Engineering &Servo Systems

HMI & SCADA Expertise

Intelligent Data& Web BasedSystems

Vision Inspection Expertise

Robotics

TEST & MEASUREMENT AUTOMATION

NI FPGA

LabVIEW Development

Test Stand Design

Machine Vision

Data Analysis & Reporting

NI Real-Time

CUSTOM SOFTWARE& HARDWARE DEVELOPMENT

PC Application Development

Product Development

Web Application, iOS, Android & App Development

Embedded Design & Programming

SDK, API & Driver Development

Database Systems

MICROSOFT CONSULTING SERVICES

10

10

5

5

INDIVIDUAL CERTIFICATIONS

WinCC OA Introduction

Siemens SCADA software portfolio

WinCC Open Architecture

WinCC V7

Standard process

visualization for

establishedmarkets

Flexible system for software OEMs and infrastructure applications

Standard system for universal use through-out all established industries

WinCC V13 (TIA Portal)

Product for new customers with scope on machine level low end demand

Ap

plicati

on

com

ple

xit

y Infrastructure &Software OEMs

HMI for new customers

Background

Started in Europe

5000 installations all over the world

Entered into US market ~ 4 years ago

WinCC OA

WinCC OA (Open

Architecture)

Distributed, redundancy requirements

Easily scalable - proper designs scale well

High speed communication requirements

Complex applications and high IO count

PLC Platform Independent

WinCC OA

WinCC OA for Oil &

Gas

Upstream

Midstream

Downstream

Distributed Generator Management

WinCC OA Case Study

Motivation for Change Current Solution Several external solutions stapled

together Upgrades and maintenance

external Regional requirements restrict

sales

Proposed Solution Single, cohesive platform, built on

a proven platform Maintaining/upgrading can be

done internally, with ownership of source code

New features and added benefits will come with new solution

Project Requirements Support revised generator designs

At Company HQ: Monitor Faults, Track Performance, etc.

Local Control for operator

Local Data Collection (with backup at HQ)

Flexible addition of new sites as operation grows

Customer ownership for future changes

Key Features

1. Distributed Architecture

2. Easily Scalable

3. Auto-generation of New Sites

4. Remote Monitoring/ GIS Viewer

5. Data Collection

6. Custom Tools & Configuration Aides

7. Multi-User, Reusable Development

8. Ultralight Client and Web UI

Key Features

1. Distributed Architecture

Case Study: Distributed Generators

HQ

ClientClient

Client

O&G: Distributed Well Sites

HQ

SiteSite

Site

O&G: Pipelines

HQ

Stations

Key Features

2. Easily Scalable

+

Case Study: Distributed Generators• Expandable into hundreds

of sites• One to dozens of

generators of varying types

• Types can vary from site to site.

• A site doesn’t have to care about changes at other locations

• Data from existing older systems can be virtualized to be viewable on new WinCC OA system.

• Integrates all operations without hardware revisions.


• Single remote site may contain a variable number of stations

• Tagged to identify with that particular site.

+Site1 Site2• Each site can have unique configurations.

• Additions/modifications only affect that one site.

O&G: Frack Site Trucks/Skids• Modular, object-oriented

• Not bound to a particular structure, may be moved and reassigned as an operation develops• Site A does not need n Skids of type 1, m skids of type 2, etc.

+B

X

Key Features

3. Auto-generation of new sites

Case Study: Distributed GeneratorsRemote site configuration handled through a custom tool

1. User selects generator type and IP address

2. System automatically builds out data points, connections, and graphics representation


3. Remote site programs configured to seek out HQ server

4. Connection made automatically

5. HQ server scans for new connections and rebuilds its data points and graphics to match


• Server needs no changes/updates as new well sites brought online

• Configuration manageable by any interface from the site (direct screen to box, web UI, mobile UI), may even be modified from the server, if those tools put in place

O&G: Frack Site Trucks/Skids• Site actively seeks new

trucks• Server needs no

specification of each new site

• Truck/skid could be scripted to auto-connect and deploy on connecting to a new site on arrival• Replaces manual

config tool

• Site seeks out HQ

• HQ pulls updates of data points

+

Key Features

4. Remote monitoring/ GIS Viewer

Case Study: Distributed Generators– Remote Viewing• Navigation available and

configurable for:• overview of all sites • single-site overview • individual generator

• Layout is dynamic• Can sort order of appearance

Case Study: Distributed Generators– Remote Viewing• Custom P&IDs and status summaries

developed for individual generator types and aggregated site data

Case Study: Distributed Generators – GIS Viewer• Map-bound overview of all active sites• Filtering of sites displayed by generator

statuses, connectivity, maintenance scheduling

O&G: Distributed Well Sites• Site representations may be filtered/stylized based on

statuses, connection, values of interest, etc.• View multiple sites in aggregated views• With proper permissions, connection to control logic

even available

O&G: Frack Site Trucks/Skids• Dynamically arrange all trucks/skids connected to a

particular site• Grouping by type, functionality, etc.• Create combined P&IDs for entire site setup using

all connected systems

O&G: Pipelines

• Monitor all stations along pipeline in relation to each other• Locate related

statuses quickly and intuitively

• Easily navigate large numbers of stations and zoom in on areas of interest

• Condense thousands of stations to a filtered, prioritized list• Find all faults, alerts,

sort by location, sensor values, etc.

Key Features

5. Data Collection


• Integrated data logging with billing activities for customer’s leased generators

• Auto-generation for usage reports

• Analysis of downtime vs. usage, power production

• Analysis of most common alerts and maintenance activities

• Reporting ranges configurable• Useful for long-term evaluation

and maintenance

O&G• Site data may be aggregated

by site, system, or device type into dedicated tags to share with HQ server

• On-station data processing to further reduce data traffic

• Robust local logging, independent of current connection

• Periodic backup to central server

• High speed data logging available

Key Features

6. Custom Tools & Configuration Aides


• DMC created architecture, but the customer is given control where revisions predicted• New site deployment• Generator parameter

assignment

• Custom tools to allow customer to make changes without touching the IDE• Plans to build extended tools

in future project phases

+

O&G: Distributed Well Sites• Scripted tools mean new

site deployments handled internally – no wait time or extra cost to bring in an integrator for each new site or hardware change

• Configuration tool could modify what calculations are run and what data is collected/relayed for each site operation without interrupting runtime

+

+

O&G: Frack Site Trucks/Skids• Nearly every

startup operation can be automated

• No need to pull in integrator for a v2 skid

• Central data analysis changeable without modifying truck/skid code

• Deployment speed much faster

B

O&G: Pipelines• Status reporting,

commands, and data aggregation customizable• E.g. may

perform analysis on-site, and only pass relevant metrics/alerts back to HQ

• Large-scale, repeating initializations, configurations, and commands may be turned into single operations

Key Features

7. Multi-User, Reusable Development


• Development environment highly conducive to code reuse

• Tools capable of bulk edits and development, reducing repetitive tasks and low-value engineering time

• Create objects, similar to blueprints, for future development.

O&G• Separate system

representations and controls can be developed in parallel, increasing rate of implementation

• Can break work down across several engineers

• Object-oriented model implicitly reuses similar features of similar devices

Key Features

8. Ultralight Client and Web UI

O&G: Pipelines• View station status on-site without having to

bring over a full HMI or monitor, and without having to install an HMI for each station• Just bring a phone or tablet and transform it

into a station UI for monitoring, configuration, etc.

Other Features & Options

SIL-3 Certified

• WinCC OA is the only available OEM SCADA platform that is SIL-3 certified

• Certified on all versions that come out for the next 3 years

Video Integration

• Unique to market - DVR-like video capture

• Can tie recorded video to alarm and events manager

• Can hold 2-3 minutes of video in circular field and then stop disposing when there is an event.

Recap

1. OA is perfect for distributed architectures

2. Scales easily as your system grows

3. Tools can be configured to auto-generate new components, make updates without needing integrator

4. Monitoring, data collecting, long-term tracking done easily

Questions?


Kristie Shea [email protected] (ex. 136) www.dmcinfo.com