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The Logo 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 Summit


New Delhi 15.11.2011

Mrs. Vidula Joshi


Technology Officer

SAN Techno Mentors Pvt Ltd

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

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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 Perspective 1.2 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 Mimic

Plant Engineers Plant Mimic

C Level Executives and Integrator/ Above Developer Production Report PLC, RTU Config Tag Mapping, Import- Export Scaling Animations Event Management Logger Config, ODBC NRDB if planned Alarm, Trend Config Server Redundancy SPC, Tracking Config Navigation SOA Support Compliance, SOE
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Process Monitoring
Process Control Alarms Trends

Process Monitoring Rejection Report


Process Control Alarms Trends Logged Data Historic Alarms Historic Rends Reports SPC Tracking Recipe Connectivity Issues OEE KPI Breakdown Analysis

Deployment

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1.4 SCADA Communication Options

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1.4 SCADA Communication options : Network

Serial

Ethernet

Proprietary
Support for Vendor Specific Communication Cards, Switches and cables

Telemetry
Support for satellite, radio or telephone communication media and protocols

Support for NIC, RS232, RS4B5 Serial Switches, Wireless Protocol, Cables Access Points, Cables, Support Industrial Ethernet Protocols

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1.4 SCADA Communication options : Protocols 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, DNP3 etc

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1.4 SCADA Communication options : OPC


SCADA Server OPC Client OPC Server

PLC/RTU

OPC Server
SCADA Server with OPC Client
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PLC/RTU

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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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1.4 SCADA Communication options : Web Technology

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
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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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1.5 Small but Important Points to Optimize SCADA Connectivity 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 ambient temperature on every tick)

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1.5 Optimize SCADA Connectivity : Open Protocol Modbus RTU

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1.5 Small but Important Points to Optimize SCADA Connectivity 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 communication troubleshooting utility. Users can also develop their own utilities.
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1.5 Optimize SCADA Connectivity : Sample Utility

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2. Outlining ROI on the system implementation

Outlining ROI on SCADA

2.1 No SCADA Vs SCADA

2.2 PLC/RTU + SCADA Vs DCS

2.3 Taking SCADA to next level

2.4 Utilizing existing Functionalities effectively


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2.1 No SCADA Vs SCADA

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-Hours 4) Standardization of processes and operations 5) Data collection, analyze and control 6) Depreciation of SCADA software is almost nil
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2.1 No SCADA Vs SCADA

Before SCADA

After SCADA

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2.1 No SCADA Vs SCADA

Start Stop Security Right Click Privilege

PASSWOR D

Food Industry Compliance Password

*******

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
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2.1 No SCADA Vs SCADA Mapping Windows Groups

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2.2 PLC/RTU + SCADA Vs DCS

1) Selection of correct Automation Technology : Reduced TCO with PLC/RTU +SCADA, Optimization
AUTOMATION TECHNOLOGY

PLC (PROGRAMMABLE LOGIC CONTROLLER) + SCADA

DCS (DISTRIBUTED CONTROL SYSTEM)

HYBRID CONTROLPAC (PROGRAMMABLE AUTOMATION CONTROLLER)


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2.1 PLC/RTU + SCADA Vs DCS

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

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2.3 Taking SCADA to next level

1) 2) 3) 4)

Control to Calculations Acquisition to Analysis Inbuilt web features with reduced engineering hours 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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2.3 Taking SCADA to next level : OEE Calculation

OEE% = Availability% x Performance% x Quality% Where: Availability% = Performance% =

actual production time possible production time


actual production optimum capacity

product produced (scrap & rework) Quality% = product produced


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2.3 Taking SCADA to next level : OEE Calculation Example


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%) Pieces Produced / (Operating Time * Ideal Rate) 413 / (373 * 80 / 60) 0.830 (83.0%) Good Pieces / Pieces Produced 390 / 413 0.944 (94.4%) Availability * Performance * Quality 0.888 * 0.830 * 0.944 0.696 Vidula Joshi (69.6%)

Performance

Quality

OEE

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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.

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

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2.4 Utilizing existing Functionalities Effectively : Useful data for MES

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2.4 Utilizing existing Functionalities effectively

Logged records are the base for Historical Alarms, Trends Action Replay Features Report Generation SPC MIS, MES layer calculations Tracking systems (many times bundled with SCADA)

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2.4 Utilizing existing Functionalities effectively

2) Action replay features (DGR) 3) COM, DCOM, Activex, Library use for standardization 4) Scalable architecture to reduce TCO and engineering manhours 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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2. 5 ROI Case

E. & J. Gallo Winery is a world-renowned wine making company. They have a subsidiary company, Gallo Glass Company, which manufactures wine bottles. The company manufactures up to one billion bottles each year in more than 100 different shapes and sizes.

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Problem Just-in-time delivery. The bottles should be available when needed to help keep the bottling and labeling operations running all the time.

How SCADA Solved 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 software connected 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).
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Problem

How SCADA Solved

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 and managers could view Key Performance Indicators (KPIs) such as defects, losses, and more. Essential to success, the system provided timely notification of defects, so that the operators could correct production and Vidula Joshi 42 boost quality.

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 energy needs 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 integration 3.3 Role of SCADA in entire business application

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3.1 Business Picture

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3.2 Control system and business system integration

ISA S95 framework defines 1) Scope of manufacturing operations and control domain 2) The organization of physical assets 3) Various models of integration 4) The information that is shared between MES and Business Functions

Business Planning & Logistics

Manufacturing Operations & Control

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3.2 Control system and business system integration ISA S95 Parts

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
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3.3 Role of SCADA in entire business application Benefit Enables faster design, development and manufacturing of new, derived products Protect your investments by using old hardware and software Increases productivity and product quality Reason Less implementation time Support for open standard Reduced maintenance hours

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3.3 Role of SCADA in entire business application Benefit Reduced expansion cost, flexibility for expansion Offer lower TCO Reduced need of custom interfaces Reason Scalable architecture At least 10 times less cost than DCS Uses industry standard technology

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3.3 Role of SCADA in entire business application Benefit Cost saving Exchanges data in data with higher layer of MIS, MES and so ERP (not directly) Mobile plant managers get connectivity with control system for watching reports
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Reason Plant floor operations are handled effectively Interface with plant wide data repository 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.

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The Logo 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

Thank You
Office No.4, Aishwarya Sankul, G.A. Kulkarni Path, Kothrud, Pune 411 038 Ph: +91 (20) 25455935 saninfo@santechnomentors.com
VISION : To create professionals with CREDENCE values for organizational and persona

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