Scada IQPC Presentation

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Vidula Joshi 1VISION : To create professionals with CREDENCE values for organizational and persona

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SAN Techno Mentors embeds success on the substrate of "CREDENCE" on

basis of which people mature, resulting in personal happiness and delight

demonstrated by their dance

SCADA India SummitNew Delhi

15.11.2011

Mrs. Vidula Joshi

Technology Officer

SAN Techno Mentors Pvt Ltd


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Utilizing the improved functionalities of SCADA to improve

core business processes

1. Optimizing SCADA connectivity and communications

2. Outlining ROI on the system implementation

3. Detailing the benefits of SCADA application on the entire

business operation


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1. Optimizing SCADA connectivity and communications

1.1 ISA S95 Business Model Communication and Functionality

Perspective1.2 Typical SCADA Architecture

1.3 SCADA Functionality Matrix

1.4 SCADA Communication options

1.5 Optimization of Connectivity & Communication


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1.1 ISA S95 Business Model Communication Perspective


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1.1 ISA S95 Business Model Functionality Perspective


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1.2 Typical SCADA Architecture


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1.3 SCADA Functionality Matrix


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Plant Operators Plant EngineersC Level Executives and

Above

Integrator/

Developer

Plant Mimic Plant Mimic Production Report PLC, RTU Config

Process

MonitoringProcess Monitoring Rejection Report

Tag Mapping,

Import- Export

Process Control Process Control OEE Scaling

Alarms Alarms KPI Animations

Trends Trends Breakdown Analysis Event Management

Logged Data Logger Config, ODBC

Historic Alarms NRDB if planned

Historic Rends Alarm, Trend Config

Reports Server Redundancy

SPC SPC, Tracking Config

Tracking Navigation

Recipe SOA Support

Connectivity Issues Compliance, SOE

Deployment


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1.4 SCADA Communication Options


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1.4 SCADA Communication options : Network

EthernetSerial TelemetryProprietary

Support for NIC,

Switches, Wireless

Access Points, Cables,

Industrial Ethernet

Protocols

RS232, RS4B5 Serial

Protocol, Cables

Support

Support for Vendor

Specific

Communication

Cards,

Switches and cables

Support for satellite,

radio or telephone

communication mediaand protocols


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Native Drivers, Vendor Specific e.g.

Siemens TCP/ IP, Mitsubishi TCP/ IP, GE Fanuc TCP/ IP

Honeywell TCP/ IP, Allen Bradley TCP/ IP, ABB TCP/ IP etc

OPC - OPC Client bundled with almost all commercial SCADA S/W

Open Standards - MODBUS RTU, MODBUS TCP/IP, IEC61850, DNP3etc

1.4 SCADA Communication options : Protocols


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SCADA

Server

OPC

Client

OPC

ServerPLC/RTU

SCADAServer

with OPC

Client

PLC/RTU

OPC Server

1.4 SCADA Communication options : OPC


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1.4 SCADA Communication options : OPC Server Add-ons


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1.4 SCADA Communication options : OPC Server Add-ons


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SCADA and Web Technology

SCADA web connectivity enables a user to

view and control SCADA screens through

the Web.

Web Server

Word html

SCADA Screen Web Screen(No separate development required)

Can send email notification,

Simple SMTP configuration, NO scripting

1.4 SCADA Communication options : Web Technology


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1.4 SCADA Communication options : Web Technology


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1.5 Optimizing Communication and Connectivity


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Make use of thin clients where possible (Only JRE required)

Use open protocols

Select multiple tag update rate as per criticalness

Log the values if required (need not to log/scan ambienttemperature on every tick)

1.5 Small but Important Points to Optimize SCADA Connectivity


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1.5 Optimize SCADA Connectivity : Open Protocol Modbus RTU


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Trend charts are intelligent to produce unsolicited points

Train your employees to use communication

troubleshooting utilities.

Many free utilities like ping and many protocol simulators

are available today.

SCADA vendor also provides communicationtroubleshooting utility. Users can also develop their own

utilities.

1.5 Small but Important Points to Optimize SCADA Connectivity


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1.5 Optimize SCADA Connectivity: Sample Utility


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Outlining ROI on

SCADA

2.1

No SCADA Vs

SCADA

2.3

Taking SCADA to

next level

2.4Utilizing existing

Functionalities

effectively

2.2

PLC/RTU + SCADA

Vs DCS

2. Outlining ROI on the system implementation


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1) Visibility

Manufacturers Yesterdays Need

I want to keep my plant running.

Manufacturers Todays Need

I need visibility of shop floor on a single dashboard.

I need single version of truth.

2) Advantages of automation are advantages of SCADA

3) Reduced Maintenance Man-Hours4) Standardization of processes and operations

5) Data collection, analyze and control

6) Depreciation of SCADA software is almost nil

2.1 No SCADA Vs SCADA


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Before SCADA

After SCADA



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PASSWOR

D

* * * * * * *

Windows Domain Security

Authenticate with Domain or local PC, Mapping existing groups

As per 21 CFR part 11 e signatures can be made compulsory for

changing critical tag value


Start Stop Security

Right Click Privilege

Food Industry Compliance Password


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2.1 No SCADA Vs SCADA Mapping Windows Groups


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1) Selection of correct Automation Technology : Reduced

TCO with PLC/RTU +SCADA, Optimization

2.2 PLC/RTU + SCADA Vs DCS

AUTOMATION

TECHNOLOGY

PLC(PROGRAMMABLE

LOGIC

CONTROLLER) +

SCADA

DCS

(DISTRIBUTED

CONTROL

SYSTEM)

HYBRIDCONTROL-

PAC

(PROGRAMMABLE

AUTOMATION

CONTROLLER)


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2) Todays SCADA offers reduced engineering hours due to

features like import export.

3) DCS features like SPC, intelligent control engine, redundancy

etc are engineered in SCADA

2.1 PLC/RTU + SCADA Vs DCS


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2.3 Taking SCADA to next level

1) Control to Calculations

2) Acquisition to Analysis

3) Inbuilt web features with reduced engineering hours

4) In data driven environment of MES systematic data and

calculations are required, part of it can be surely handled by

SCADA e.g. OEE, KPI, Breakdown Analysis

5) SCADA is more than HMI, can perform calculations, can

manage events and can talk to field devices directly if

required.


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OEE% = Availability% x Performance% x Quality%

actual production time

possible production time

actual production

optimum capacityproduct produced (scrap & rework)

product produced

Availability% =

Performance% =

Quality% =

Where:

2.3 Taking SCADA to next level : OEE Calculation


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Planned Production Time = Shift Length - Breaks = 480 - 15 - 15 - 30 = 420 minutes

Operating Time = Planned Production Time - Down Time = 420 - 47 = 373 minutes

Good Pieces = Pieces Produced - Reject Pieces = 413 - 23 = 390 pieces

Availability = Operating Time / Planned Production Time

= 373 minutes / 420 minutes= 0.888 (88.8%)

Performance = Pieces Produced / (Operating Time * Ideal Rate)

= 413 / (373 * 80 / 60)

= 0.830 (83.0%)

Quality = Good Pieces / Pieces Produced

= 390 / 413

= 0.944 (94.4%)

OEE = Availability * Performance * Quality

= 0.888 * 0.830 * 0.944

= 0.696 (69.6%)

2.3 Taking SCADA to next level : OEE Calculation Example


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2.4 Utilizing existing Functionalities effectively

1) Interface with plant wide data repository ( Historian)

Historian is a high

performance data archiving

system designed to

efficiently collect, store,and retrieve time-based

information at extremely

high speed.

Utilizing existing Functionalities Effectively : Database logger : Single version of truth


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Utilizing existing Functionalities Effectively : Database logger : Single version of truth

2 4 Utilizing existing Functionalities Effectively : Useful data for MES


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2.4 Utilizing existing Functionalities Effectively : Useful data for MES


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Logged records are the base for

Historical Alarms, Trends

Action Replay Features

Report Generation

SPC

MIS, MES layer calculationsTracking systems (many times bundled with SCADA)



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2) Action replay features (DGR)

3) COM, DCOM, Activex, Library use for standardization4) Scalable architecture to reduce TCO and engineering man-

hours

5) Standard procedures and scripts

6) Calculation tag

7) Can accept and process file data

8) Selection of appropriate SCADA options depending upon

industry vertical


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E. & J. Gallo Winery is a world-renowned wine making

company. They have a subsidiary company, Gallo Glass

Company, which manufactures wine bottles. The companymanufactures up to one billion bottles each year in more than

100 different shapes and sizes.

2. 5 ROI Case

Problem How SCADA Solved


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ob e o SC So ed

Just-in-time delivery. The bottles

should be available when needed

to help keep the bottling andlabeling operations running all the

time.

SCADA collected and presented

data from all steps in bottle making

batch, furnace, fore-hearth,inspection and packing. The system

provided quick, graphical reports

via the Internet. With an open

architecture, the softwareconnected to the existing base of

equipment at the site such as

sensing and inspection devices,

Programmable Logic Controllers

(PLCs), scales and timing systems

and communicated over Ethernet

(TCP/IP).

Problem How SCADA Solved


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SCADA worked in conjunction with

a database to consolidate the data

from the plant floor devices, then

transformed that real-time data

into dynamic text, alarm, and

graphic displays. Operators andmanagers could view Key

Performance Indicators (KPIs) such

as defects, losses, and more.

Essential to success, the systemprovided timely notification of

defects, so that the operators

could correct production and

boost quality.


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As a result of this solution, the company was able to save $5

million annually, increase production by five percent, and

reduce defects by 25 percent. It also lived up to its

commitment to environmental protection by lowering energyneeds and furnace emissions.


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3. Detailing the benefits of SCADA application on the entire

business operation

3.1 Business Picture

3.2 Control system and business system integration3.3 Role of SCADA in entire business application


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3.1 Business Picture


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Business Planning

& Logistics

Manufacturing

Operations &Control

ISA S95 framework defines

1) Scope of manufacturing operationsand control domain

2) The organization of physical assets

3) Various models of integration

4) The information that is shared

between MES and Business Functions

3.2 Control system and business system integration


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Part 1 : Standard Terminology & Models

Part 2 : Object Models

Part 3 : Activity Models

Part 4 : Object Models and Attributes

Part 5 : Business to Manufacturing (B2M) Transaction

3.2 Control system and business system integration ISA S95 Parts


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Benefit Reason

Enables faster design, development and

manufacturing of new, derived products

Less implementation

time

Protect your investments by using old

hardware and software

Support for open

standard

Increases productivity and product

quality

Reduced maintenance

hours

3.3 Role of SCADA in entire business application


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Benefit Reason

Reduced expansion cost, flexibility for

expansion

Scalable architecture

Offer lower TCO At least 10 times less

cost than DCS

Reduced need of custom interfaces Uses industrystandard technology



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Benefit Reason

Cost saving Plant floor operations

are handled effectively

Exchanges data in data with higher

layer of MIS, MES and so ERP (not

directly)

Interface with plant

wide data repository

Mobile plant managers get connectivity

with control system for watching

reports

Web support, Drill

down analysis



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Acknowledgement

Information used in this presentation has been obtained from public

domain / published sources / catalogs of manufacturers. It is used solely

for the purpose of illustration and presentation only.

Contribution of these manufacturers / publishers in this presentation is

hereby acknowledged with thanks.

The terminologies / symbols used in this presentation belong to the

respective developers / manufacturers / professional organizations and

are duly acknowledged with thanks.

We thank the organizers of the SCADA India Summit 2011 for the

opportunity given to present in the conference.

We thank the audience for patient listening and keen interest in the

subject.

The Logo


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Thank You

Office No.4, Aishwarya Sankul, G.A. Kulkarni Path, Kothrud,

Pune 411 038 Ph: +91 (20) 25455935

[email protected]

SAN Techno Mentors embeds success on the substrate of "CREDENCE" on

basis of which people mature, resulting in personal happiness and delight

demonstrated by their dance
mailto:[email protected]:[email protected]

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Scada IQPC Presentation