improving and scaling scada systems: is wincc oa right for me?
TRANSCRIPT
Improving and Scaling SCADA Systems:Is WinCC OA Right for Me?James Condon – DMC, Inc.
Unrestricted © Siemens, Inc. 2015 All rights reserved. Answers for industry.
Agenda
Introduction
WinCC Open Architecture (OA) Overview
Case Study Presentation Distributed System
Project Example Applying solution to
O&G
Questions
Presenter InfoJames Condon
Project Engineer
Siemens Certified Professional
Certified WinCC OA Engineer
B.S. in Mechanical Engineering
University of Illinois in Urbana-Champaign
With DMC since 2011
DMC Company Profile
Industries Served:
Oil & Gas
Automotive
Chemical and Food
Processing
Electronics/Semicondu
ctor
Hydraulics
Machine Tool
Material Handling
Metal Converting
Packaging
Pharmaceutical
Printing & Textiles
Laboratory Testing
Established in 1996, offices in Chicago, Boston, NY, Denver, Houston & customers
throughout the world
employees & growing
80+
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
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.
O&G: Distributed Well Sites
• 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
Case Study: Distributed Generators
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
O&G: Distributed Well Sites
• 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
Case Study: Distributed Generators
• 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
Case Study: Distributed Generators
• 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
Case Study: Distributed Generators
• 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
Case Study: Distributed Generators
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?
Unrestricted © Siemens Industry, Inc. 2015 All rights reserved.
James Condon [email protected]
www.dmcinfo.com