Download - Scada IQPC Presentation
-
7/31/2019 Scada IQPC Presentation
1/53
Vidula Joshi 1VISION : To create professionals with CREDENCE values for organizational and persona
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 SummitNew Delhi
15.11.2011
Mrs. Vidula Joshi
Technology Officer
SAN Techno Mentors Pvt Ltd
-
7/31/2019 Scada IQPC Presentation
2/53
Vidula Joshi 2
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
-
7/31/2019 Scada IQPC Presentation
3/53
Vidula Joshi 3
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
-
7/31/2019 Scada IQPC Presentation
4/53
Vidula Joshi 4
1.1 ISA S95 Business Model Communication Perspective
-
7/31/2019 Scada IQPC Presentation
5/53
Vidula Joshi 5
-
7/31/2019 Scada IQPC Presentation
6/53
Vidula Joshi 6
1.1 ISA S95 Business Model Functionality Perspective
-
7/31/2019 Scada IQPC Presentation
7/53
Vidula Joshi 7
-
7/31/2019 Scada IQPC Presentation
8/53
Vidula Joshi 8
1.2 Typical SCADA Architecture
-
7/31/2019 Scada IQPC Presentation
9/53
Vidula Joshi 9
-
7/31/2019 Scada IQPC Presentation
10/53
Vidula Joshi 10
1.3 SCADA Functionality Matrix
-
7/31/2019 Scada IQPC Presentation
11/53
Vidula Joshi 11
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
-
7/31/2019 Scada IQPC Presentation
12/53
Vidula Joshi 12
1.4 SCADA Communication Options
-
7/31/2019 Scada IQPC Presentation
13/53
Vidula Joshi 13
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
-
7/31/2019 Scada IQPC Presentation
14/53
Vidula Joshi 14
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
-
7/31/2019 Scada IQPC Presentation
15/53
Vidula Joshi 15
SCADA
Server
OPC
Client
OPC
ServerPLC/RTU
SCADAServer
with OPC
Client
PLC/RTU
OPC Server
1.4 SCADA Communication options : OPC
-
7/31/2019 Scada IQPC Presentation
16/53
Vidula Joshi 16
1.4 SCADA Communication options : OPC Server Add-ons
-
7/31/2019 Scada IQPC Presentation
17/53
Vidula Joshi 17
1.4 SCADA Communication options : OPC Server Add-ons
-
7/31/2019 Scada IQPC Presentation
18/53
Vidula Joshi 18
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
-
7/31/2019 Scada IQPC Presentation
19/53
Vidula Joshi 19
1.4 SCADA Communication options : Web Technology
-
7/31/2019 Scada IQPC Presentation
20/53
Vidula Joshi 20
1.5 Optimizing Communication and Connectivity
-
7/31/2019 Scada IQPC Presentation
21/53
Vidula Joshi 21
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
-
7/31/2019 Scada IQPC Presentation
22/53
Vidula Joshi 22
1.5 Optimize SCADA Connectivity : Open Protocol Modbus RTU
-
7/31/2019 Scada IQPC Presentation
23/53
Vidula Joshi 23
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
-
7/31/2019 Scada IQPC Presentation
24/53
Vidula Joshi 24
1.5 Optimize SCADA Connectivity: Sample Utility
-
7/31/2019 Scada IQPC Presentation
25/53
Vidula Joshi 25
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
-
7/31/2019 Scada IQPC Presentation
26/53
Vidula Joshi 26
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
-
7/31/2019 Scada IQPC Presentation
27/53
Vidula Joshi 27
Before SCADA
After SCADA
2.1 No SCADA Vs SCADA
-
7/31/2019 Scada IQPC Presentation
28/53
Vidula Joshi 28
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
2.1 No SCADA Vs SCADA
Start Stop Security
Right Click Privilege
Food Industry Compliance Password
-
7/31/2019 Scada IQPC Presentation
29/53
Vidula Joshi 29
2.1 No SCADA Vs SCADA Mapping Windows Groups
-
7/31/2019 Scada IQPC Presentation
30/53
Vidula Joshi 30
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)
-
7/31/2019 Scada IQPC Presentation
31/53
Vidula Joshi 31
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
-
7/31/2019 Scada IQPC Presentation
32/53
Vidula Joshi 32
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.
-
7/31/2019 Scada IQPC Presentation
33/53
Vidula Joshi 33
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
-
7/31/2019 Scada IQPC Presentation
34/53
Vidula Joshi 34
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
-
7/31/2019 Scada IQPC Presentation
35/53
Vidula Joshi 35
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
-
7/31/2019 Scada IQPC Presentation
36/53
Vidula Joshi 36
Utilizing existing Functionalities Effectively : Database logger : Single version of truth
2 4 Utilizing existing Functionalities Effectively : Useful data for MES
-
7/31/2019 Scada IQPC Presentation
37/53
Vidula Joshi 37
2.4 Utilizing existing Functionalities Effectively : Useful data for MES
-
7/31/2019 Scada IQPC Presentation
38/53
Vidula Joshi 38
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)
2.4 Utilizing existing Functionalities effectively
-
7/31/2019 Scada IQPC Presentation
39/53
Vidula Joshi 39
2.4 Utilizing existing Functionalities effectively
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
-
7/31/2019 Scada IQPC Presentation
40/53
Vidula Joshi 40
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
-
7/31/2019 Scada IQPC Presentation
41/53
Vidula Joshi 41
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
-
7/31/2019 Scada IQPC Presentation
42/53
Vidula Joshi 42
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.
-
7/31/2019 Scada IQPC Presentation
43/53
Vidula Joshi 43
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.
-
7/31/2019 Scada IQPC Presentation
44/53
Vidula Joshi 44
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
-
7/31/2019 Scada IQPC Presentation
45/53
Vidula Joshi 45
3.1 Business Picture
-
7/31/2019 Scada IQPC Presentation
46/53
Vidula Joshi 46
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
-
7/31/2019 Scada IQPC Presentation
47/53
Vidula Joshi 47
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
-
7/31/2019 Scada IQPC Presentation
48/53
Vidula Joshi 48
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
-
7/31/2019 Scada IQPC Presentation
49/53
Vidula Joshi 49
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
3.3 Role of SCADA in entire business application
-
7/31/2019 Scada IQPC Presentation
50/53
Vidula Joshi 50
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
3.3 Role of SCADA in entire business application
-
7/31/2019 Scada IQPC Presentation
51/53
Vidula Joshi 51
-
7/31/2019 Scada IQPC Presentation
52/53
Vidula Joshi 52
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
-
7/31/2019 Scada IQPC Presentation
53/53
Thank You
Office No.4, Aishwarya Sankul, G.A. Kulkarni Path, Kothrud,
Pune 411 038 Ph: +91 (20) 25455935
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]