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Isolated IntegrationIsolated Integration

A Multi-layered Fiber Network for Communication installed in the Slab Group, Sparrows Point Division, Bethlehem Steel

Corporation

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What Is Isolated Integration?

Isolated Integration is a term that has been applied to the basic idea and base-line operational requirements of the multilayer fiber network currently installed and in use by the Bethlehem Steel Corporation, Sparrows Point Division’s Slab Group.

Several Basic Operational Requirements Were:

Base Operational Requirements

Capable of handling multiple data types

Level 2 Operating Data

Level 0 – 1 Machine Control Data

General Office Communications

Production and Training Video

Base Operational RequirementsKeep data integrity and security by isolating the various types

GSE Control Levels A and B needed complete separation

BOF Allen-Bradley PLC Cimplicity HMI control system isolated

General Office Data (Non-Production Critical)

Production and Training Video (Least Critical)

Base Operational RequirementsFlexibility to allow for expansion and network wide connectivity

Approximately 90% of Installed Machine base is covered by the phase 1 network cabling

Personnel moves require connectivity to previously used data in spite of location

Daily request for additional network connections

New, previously unheard of data availability

Base Operational RequirementsNo dead ends or network limitations

Did not want to run more back bone fiber or upgrade network equipment hardware

Ability to add new data types without band width or architecture concerns

Ability to add new operation areas by merely running copper or fiber to them

Base Operational Requirements

Capable of handling multiple data typesKeep data integrity and security by isolating the various typesFlexibility to allow for expansion and network wide connectivityNo dead ends or network limitations

Network Architectural Requirements:

Network Architectural Requirements

Use existing Interconnect Cabinets IC601/IC602 with upgraded Cisco Catalyst Routers established during initial backbone installation

48 Strand Multimode fiber – installed, terminated and tested to comply with Lucent Technologies Standards. Lower strand count to non production critical single ended dropsDual Homed Signal sourcing to give connection redundancy

Network Architectural Requirements (cont.)

Minimum CAT5+ copper terminations, capable of transferring data at 100 megabits and abovePrimary End User Connection to be copper with minimal local fiber runsSingle Ended (Non Redundant) Fiber drops for non-production critical end users

Layout with Coverage Spheres

MC600

SP 686

SP 684

SP 687

SP 683TC 653

SP 679

SP 681

SP 677

SP 692

IC602SP 682

SP 688

IC 601

SP 675

SP 689

SP 690SP 693

Slab Group Layout

MC600

SP 686

SP 684

SP 687

SP 683TC 653

SP 679

SP 681

SP 677

SP 692

IC602

SP 682

SP 688

IC 601

SP 675

SP 689

SP 690SP 693

Multi-Layered CakeDepending upon the coverage area and connection requirements of the individual Switch Points (SP’s), various Cisco 2924 Catalyst Switch combinations can be placed in the cabinets. In this diagram each colored slice represents a separate Cisco 2924 switch

Economical and Flexible

These combinations have allowed the Slab Group to implement a robust, flexible but economical solution to empower local operations and support personnel with real time process data.

Leading Edge TechnologyBuilding on this foundation of proven Cisco router and switch technology and through the use of their VLAN capabilities, we were further able to limit expenditures in low machine population areas by subdividing the switches to support a multitude of secure, isolated networks

Mix and Match Networking

Flexible Local EmpowermentA typical SP Cabinet, this one from the installed base in the Caster, may look similar to this. Multiple layers of Cisco equipment with one of the 2924’s subdivided into the General Office VLAN and the Video VLAN due to the requirements of the area and end users

Hardware Blends

1 2 3 4 5

Bar graph

Satellite dish

Video 1 2 3 4 5

Bar graph

Population Growth in 3 Years

8+ Mid-Large System

150+ Desktop/Lapto

p PC’s

25+ GE /AB PLC Racks

Video

Video

Video

14 Networked Process Video Cameras

5 Operator Entry Displays

10 - 15 Network Printers

PLUS…

Population Growth in 3 Years Cont.

4 Separate Microsoft SQL Servers 3 Unique Web Servers Complete DCS Level 1 Caster Control System BOF Level 0-1 HMI Based Ethernet Control System 4 Wireless Ethernet access points with connections to

BOF Charge Cranes for line-up information Addition of Vessel Lasers to update Pulpit Operators of

Lance bias’ and lining conditions via Wireless Ethernet 4 Remote Magnetic Tag Readers to monitor Scrap

Haulers 1 Oracle Based Data Warehouse

Isolated Integration On a side note – 2 Stories of the

usefulness of the network and it’s capabilities.

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BOF HMI Ethernet Control

Remote DB Repair and HMI Reboot

What Is Isolated Integration?

Isolated Integration is a term that has been applied to the basic idea and base-line operational requirements of the multilayer fiber network currently installed and in use by the Bethlehem Steel Corporation, Sparrows Point Division’s Slab Group.

For the Slab Group, This is the way we keep our i on the

FUTURE

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Isolated Integration This Network Design could not have

been possible without a true team effort between:

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Local and Corporate EDS personnel

BSC Corporate IT Personnel

BSC SP Slab Group and IT Members

Isolated Integration Thank You

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