s a instrumentation and control: scada review 2015 wonderware

S A Instrumentation and Control: Scada Review 2015

2015 Copyright Technews Publishing (Pty) Ltd – www.technews.co.za All rights reserved

Wonderware

End-user details Name: Details withheld at reviewer request

SI details Name: Warren Hofland

Designation: Systems Engineer

Company: Convenient Software Solutions (Pty) Ltd

Phone: +27 (0)31 914 0040

E-mail: [email protected]

Product details Product name and version: System Platform 2012 R2

Vendor: Wonderware

Phone: +27 (0)11 607 8100

E-mail: [email protected]

URL: www.wonderware.co.za

Application details Location: Port of Durban, Durban, KZN

Industry: Logistics

Date project started: 2013-04

Date project completed: 2014-01

Application: Control and monitoring of Medium Voltage distribution and

standby diesel power generation

Server OS: Windows Server 2008 R2

Client OS: Windows 7 Professional

Application statistics Tag count: >5000

Updates per day: Approx. 7 200 000

Disk space for one day’s updates: 20MB

Physical I/O count: 1600 * Digital

400 * Analog

Front ends: 13 * Schneider Electric PLCs

8 * Schneider Electric remote I/O stations (all PLC I/O

remote)

Licences: 1 * Application Server 2012 R2 25 000 I/O

1 * Development Studio

2 * Device Integration Servers 2012 R2

1 * Wonderware Historian Server

5 * Wonderware Historian Client + 3 * Add on client

licenses

16 * InTouch for System Platform



1 * Software Toolbox OPC

13 * Modbus Suite drivers

Scada configuration man-hours: 300 man hours

[Heading1] End–user responses

[Heading2]General

Q: Briefly describe the application including information on any pre-existing control system.

The application involved the expansion of an existing Wonderware InTouch scada system to include

Wonderware’s ArchestrA-based System Platform, Historian and Schneider hot-standby PLCs. The system monitors

and controls 9 MV (11kV & 6.6kV) substations and 4 2.5 MVA standby diesel generators at the Port of Durban

over an area of approximately 30 square km.

In the event of loss of power supply from the grid, the SCADA system has full monitoring of the port’s electrical

reticulation, giving the control officer correct information to switch on standby supplies or adjust reticulation

feeds to resupply the port with power. Automatic sequences can restore power to the port by monitoring the loss

of grid power and automatically setting up the electrical network to start up diesel generator power. This reduces

the downtime of incoming/outgoing harbour shipping traffic and ship loading as no power results in the complete

standstill of both shipping and trucking throughout the port and costs in the order of R20m per hour.



Q: What was the primary motivation for the project?

To improve Port Authority asset availability in the face of electrical supply uncertainty from the grid.

Q: What were the main goals established for the project?

1. To mitigate the effects of power disruptions and to improve safety.

2. Reduce port downtime related to power supply disruptions.

3. Provide remote access and safe, secure switching of reticulation.

Q: In the procurement decision making process what were the primary considerations that influenced the

product selection?

Existing track record with Wonderware solutions and Wonderware Southern Africa, support from the vendor and

local support from SI. Product scalability, versatility, redundancy features and favourable TCO.

Q: What Project Management principles and/or methodologies did you employ as end-user to mitigate risk,

ensuring the project came out on time and within budget?

The project management was handled by Transnet through weekly project review and progress meetings with all

associated parties.

Licensing, maintenance & support

Q: What upgrade agreements are in place for this application?

Upgrades are covered under a paid annual maintenance agreement.

Q: How is after-sales support handled on this application?

Support is covered under a paid annual support agreement and includes remote desktop support, site visits and

system maintenance.

Q: Do you have a documented process in place to manage, test and install OS and scada system software

patches?

Response omitted as answered by SI, not end-user.

Integration, reporting and archiving

Q: Is the scada system integrated onto an intranet or the Internet?

The system can be remotely accessed for control in emergency situations via a VPN login connection, allowing

remote desktop access to relevant control scada stations.

Q: Does the system include or interface with an expert system?

No.

Q: Does the system include any form of augmented cognition (AC) or augmented reality (AR)?

No.

Q: Is the system integrated with an MES / ERP or other management reporting or control system?

No.



Q: Has any GIS (Geographic Information Systems) functionality been configured in the application?

No.

Q: Has any asset management functionality been configured in the application (for software assets, control

system assets or for plant assets)?

No.

Q: Do you run the scada in conjunction with any other third-party application software?

IFM vibration monitoring software monitoring generator bearings and Cogent Datahub software package to

SMS/email critical alarms to management/standby.

Q: Does the application include data archiving / historian capabilities with an historical data reporting system?

The system uses Wonderware’s real-time Historian as well as Historian Client and Wonderware Information

Server for reporting. This combination provides data logging with down to 20msec resolution if required while

also making it easy to define user-generated and informative reports.

Maintenance, reliability and asset optimisation

Q: Have any production benchmarking tools been configured as part of the scada system?

No.

Q: What maintenance, reliability, asset optimisation and/or continuous improvement criteria were included in

the user requirements specification for this project?

Introduced reporting and data for operation and efficiency analysis.

Mobile device support

Q: Are you currently using tablets, mobile phones or other smart mobile devices to interact with the scada

system?

No.

Q: Do you allow users to interface with the scada system via their own personal smart devices? (BYOD)

No.

End-user conclusion

Q: What was the predominant feature (or features) that made you decide to purchase this scada product over

all others for this application?

Scalability, versatility, redundancy features and favourable TCO.

Q: What was the most significant change that you implemented in scada engineering practice / technology in

this project?

The peer-to-peer Application Object Server (AOS) strategy with 13 local AOSs failing over to a centralised standby

AOS. This is not the typical 2 AOS servers running side by side in parallel redundancy. This architecture was

motivated by the 30 square kilometre area of port operations and the need for redundancy at each area.



Q: What single operational feature most impresses you about the product now that it is in operation?

The adopted Wonderware solutions readily lend themselves to easy implementation and rapid reconfiguration to

cater for changing needs.

Q: What impresses you most about the architecture?

Redundancy, hot standby, remote access with stable security and ease of modification,



SI responses

Project details

Q: What tools were used to minimise the man-hours taken?

The specification of standards as per the ArchestrA model, pre-developed standards of field instrumentation and

electrical equipment.

Q: Do the operator interfaces on this project use multi-touch gestures?

No.

Q: What human factors were taken into consideration as principles or development standards in the HMI

design process?

Navigation is designed to minimise the number of clicks to get to the full information for the targeted device.

Colours used are minimised pastel colours for process layouts with brighter colours used to prompt operator

action. Process screens are simplistic and minimal to show key data for running operations with more detail

available inside faceplate objects.

Q: For the graphics development process did you use standard library images, or did you have to draw images

from scratch?

Where applicable, standard library objects were used.

Q: How would you describe the library of graphic images?

Comprehensive for most needs.

Q: Did you use any ‘special’ images?

Yes, photographs and map layouts.

Q: Did you use any video or multimedia technology in the application?

No.

Q: What alarm management standards or best practices were adopted in configuring the scada system alarms?

Best practices were followed in reducing alarm count for non-critical indications, graphical filtering of alarms to

allow operator for area-specific alarms, alarm diagnostic information leading operator to fault - all following ISA

18.2 principles.

Q: What structured processes were followed to determine expected performance under full load, and during

abnormal failure conditions?

Response off topic.

Q: What are the key physical communication layers and communication protocols employed in the system?

Ethernet over fibre and copper, Ethernet dual-redundant ring over fibre and wireless radio telemetry for

monitoring purposes.

Q: What is the network speed and communications medium of the slowest link in this project’s scada network?

10Mbit/s over copper.



Q: What is the network speed and communications medium of the fastest link in this project’s scada network?

1Gbit/s over fibre.

Q: What levels of redundancy are incorporated in this scada application?

Each of the 13 local PC stations are the AOS (I/O server) for their area’s remote I/O. Should the local station fail, it

will do so to the centralised communication AOS server. The 42km fibre optic network ring between all key sub

stations and control areas is redundant. Critical processes run on hot-standby controllers.

Q: What specific custom code or scada scripts were written for this project?

Scripting was used for varying switchgear operating security rights.

Project management

Q: What Project Management principles and/or methodologies did you as SI employ to mitigate risk and to

ensure the project came out on time and within budget?

We followed a four-stage project methodology: initiation, planning, implementation and closure. We reduced re-

engineering by ensuring that the preceding step was completed and signed off before moving into the next

development phase. FAT simulations and testing for various conditions including faults reduced the risk at hot

commissioning.

Security and data protection

Q: How have authentication, authorisation and role management been configured?

We incorporated System Platform-based security roles e.g. operators, supervisors, managers and administrators.

Q: Does the design make provision for a DMZ and firewall segregation of process (scada) network and business

networks?

A VLAN was created for the process network which is a DMZ area.

Q: What intrusion detection has been incorporated on the plant network(s) on which this scada system exists?

Cisco-based intrusion detection was incorporated to log any attempted unauthorised access.

Q: Is the security model employed based on a standard?

No.

Q: In what ways is this project’s hardware architecture optimised for patch management and antivirus

management?

Response off topic.

Q: What configuration back-up and data archive backup methodologies have been adopted?

Backups are done on changes made during project modifications and are stored on local machine, off site in the

depot office and SI-support system backup servers. A quarterly backup of all servers’ bare metal backup as well as

PLC code and scada development and objects backup is performed. The historian server data files are also stored

in these backups.



Q: Did you use any integrated or third party configuration control system for the scada configuration during the

engineering of this application?

Yes. MS Access designed tag tool software developed in house to automatically create the import and export of

both PLC and scada objects as well as address allocations and variable-based tags.

SI conclusion

Q: What impresses you most about the architecture?

The ease with which the architecture scales from a simple client-server to a multi-tier application capable of

installation on this geographically large site, centralised development, scalability for massive future expansion

expectations.

Q: What impresses you the most about the engineering / configuration aspects of the product now that it is in

operation?

Response off topic.

Q: How would you rate the ease of use of the historical reporting system?

Simple to use.



Vendor responses

Product Current version Subject project - used

Product version / Module versions Wonderware System Platform 2014

R2

Wonderware System Platform

2012 R2

Q: Vendor comments on product / modules?

Wonderware System Platform offers excellent ease of use, template objects and connectivity capabilities across

multiple platforms.

Operating systems / VMware Product response - supported Subject project - used

Operating systems – client side run-

time?

Windows 8

Windows Server 2012

Windows 7 Professional

Operating systems – client side

configuration?

Windows 8

Windows Server 2012

Windows Server 2008 R2

Operating systems – server side? Windows Server 2012 Windows Server 2008 R2

Browser based?

Wonderware Information Server

which forms part of ArchestrA

System Platform has the capabilities

to host process graphics to be

browsed by a web browser

InTouch Access Anywhere allows

control of the HMI/scada from any

HTML 5-compatible browser and

forms part of ArchestrA System

Platform

Partial

Front end device communications

protocols

OPC

.NET APIs

OLEDB connectivity

3rd party .NET controls

Modbus TCP/IP Ethernet

OPC DA Client

Does the scada system rely on Java

plug-ins to exploit the full

functionality of its core and

additional modules?

No N/A

Q: Vendor comments on operating systems

Microsoft provides Wonderware with architectural guidance, development and technical support, product

roadmap coordination and scalability testing of Wonderware software solutions, ensuring that the Wonderware

product suite is coordinated with the Microsoft development roadmap.

Licensing, maintenance & support model

Q: What sort of licensing agreement options are offered?

Only those licences applicable to the modules necessary for a system’s operation need be purchased.

Licenses are based on the functionality or modules that are required for the specific solution. Each license is

bought for each component of the system, so all options are available and the customer need only purchase the

licences necessary for the required functionality of the system.



Q: Are licences sold outright or subject to periodic (e.g. annual) renewal?

Licensing is a once-off purchase for a particular version.

Q: What upgrade agreements are offered?

The annually renewable Customer FIRST Support and Services Program helps clients protect and extend the value

of Invensys products and solutions. Patches and version upgrades are available at no-charge as part of the

program.

Q: What after-sales offerings iro support and maintenance are available, and which technologies are used to

deliver them?

Support is covered under a paid annual support agreement and includes remote desktop support via VPN, e-mail

and telephonic response. Wonderware also offers advanced remote monitoring technology that enhances the

vendor’s ability to deliver higher availability and reliability of plant assets to the client company.

Key features of the advanced remote monitoring offering include:

24/7/365 remote monitoring and notification of issues

Detection and rectification of issues or problems before they become mission-affecting

Clear and regular reports providing insight into the operation of Wonderware applications, possible

improvements, anti-virus reporting, Wonderware and Microsoft patch management and OS system platform

support

Q: Do you have a documented process in place to manage and test OS patches and to release scada system

software patches?

Wonderware tests its products on platforms that are configured with all cumulative Microsoft Updates to-date.

The goal of Wonderware is to support Microsoft Security Updates within 15 business days of release. Any

exceptions to this are listed on the Wonderware Security Central Web page.

Technology incorporated Product response Subject project

Product uses Web Services?

Some modules (e.g. Wonderware

MES) use Windows Communication

Foundation

Yes.

Used for Engineering of

communication modules,

monitoring of Ethernet

switches and monitoring of

Wonderware Information

Server for reporting and data.

Cloud computing supported?

SmartGlance mobile reporting,

Wonderware Historian and Workflow

components utilise cloud computing

technology

No

Virtualisation models supported? Fully supported on VMware and

Microsoft Hyper V Technologies

No

Multi-touch gestures supported by

OS + scada hardware + scada

software?

No No



Q: What new technology has been introduced into the product in the last 12 months?

ArchestrA System Platform 2014 R2 has introduced, inter alia:

New animation capabilities

Situational awareness technology

Improved script editor and script exception handling features

XML import and export capability for graphical elements

HTML 5 support

Support for Windows 8, Windows Server 2012 and Windows 7 embedded

InTouch Access Anywhere for visualisation with zero client installation enables users to securely troubleshoot

plant equipment from any location, on any device, at any time

Integration and reporting

Q: What generic and/or product specific interfaces does the product have iro well-known MES packages?

Web Services, File Drop, FTP, MSMQ, XML, HTTP, and SOAP, B2MML, MS SQL Server, SAP (SAP Netweaver

certification), SYSPRO e.NET interfaces, OPC UA and OPC .NET v4.0.

Q: What native historical data reporting options are available?

Wonderware Historian Client generates data charts and reports directly from the Wonderware Historian. Reports

and data charts from Wonderware Historian Client can be integrated with information from other Wonderware

applications and made available over the Web using Wonderware Information Server.

Reporting solutions include:

Table Weaver - dynamic, drill-through reports and data displays

Wonderware Performance - OEE and equipment downtime reports and KPI dashboards

Wonderware Operations – multiple reporting options

Maintenance, reliability and asset optimisation

Q: What maintenance, reliability, asset optimisation and/or continuous improvement related modules or

capabilities does the product incorporate?

None.

PLC configuration and programming

Q: What capabilities does the scada offer in terms of generation and/or management of PLC configuration files

or PLC application code?

Wonderware System Platform can auto-assign PLC addresses to configured field inputs, keeping the functionality

of maintaining the PLC tag database at the PLC level.

Security and data protection

Q: If the scada system generates application files that are transferred to the PLC, how are PLC virus attacks

prevented in this process?

N/A.



Q: What authentication, authorisation & role management models are available for the runtime environment?

Roles and privileges are configured in Wonderware System Platform, Wonderware MES and Wonderware

Information Server or through Microsoft Active Directory.

Unique selling proposition (USP)

Q: List the top five feature/benefit pairs that contribute to this product’s USP.

Feature Benefit

Pre-developed object standards Drastically reduced engineering time, improved

engineering accuracy, faster project roll-outs

Scada system scalability

Accommodates technology growth and project

expansion expectations

Central configuration point

Reduced costs for project implementation and

maintenance

s a instrumentation and control: scada review 2015 wonderware

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