IEEE PES MeetingMarc L. HunterFoxboro A2 Automation Platform Business ManagerNorth American

Agenda

Discussion of DCS, PLC, SCADA, and Hybrid control systems

Markets served by various technologies Hybrid control system advantages in Water and Waste

Water Technology Future of Invensys – setting the pace for

automation industry Homeland Security

Distributed Control

“A design approach in which factory or machine control is divided into several sub-systems, each managed independently by a unique programmable controller or other control system, yet all interconnected to form a single entity. Individual subsystems may be interconnected via communications networks.”

» Patrick-Turner Industrial Automation Dictionary, 1996

Distributed Control System Advantages

Fault tolerant controllers Redundant input/output card capabilities Redundant communications Advanced control configuration Integrated human machine interface Industry domain expertise Program control security

Programmable Controller

“A solid state industrial control device, member of the computer family, designed specifically to be programmed to perform relay logic functions, timing, counting, arithmetic, and data manipulation, all for the purpose of implementing control over industrial machines and processes. The programmable controller consists of a central processor, memory system, input/output system, and power supply, all of which are designed to operate in harsh industrial environments.”

» Patrick-Turner Industrial Automation Dictionary, 1996

Programmable Logic Controller Advantages

Easy to use and install Distribution network – local electrical supply house Inexpensive Electrician can diagnose and upgrade ADEQUACY

SCADA

Supervisory Control – “A control scheme whereby a computer or controller monitors and intermittently downloads programs, sets sub-goals, or adjusts control parameters of a lower level automatic controller.”

Data Acquisition – “The process of collecting data from the system through some manual or automatic means for the purpose of producing printed reports for operating, supervisory, maintenance, or accounting disciplines.”

» Patrick-Turner Industrial Automation Dictionary, 1996

SCADA Advantages

Integrated package – communications and control Tailored to specific application Niche market domain expertise Key attributes within communications Economical

Hybrid Control System

“A control system that takes the advantages of all different control system hierarchies and feature sets to combine into a new revolutionary approach for solving control and integration issues in today’s competitive manufacturing and processing industries.”

» Marc L. Hunter; MBA, MS Automation

“The power and performance of a DCS at the price and ease of use of a PLC”

» Invensys Foxboro

Hybrid Control System Advantages

All advantages of DCS, PLC, and SCADA rolled into one– Redundant communications and controllers– Advanced control configuration – IEC 61131– Integrated human machine interface– Industry domain expertise– Program control security– Easy to use and install– Inexpensive– Electrician can diagnose and upgrade

DCS - PLC - PC/PLC Traditional Report Card

WARNING! GENERALIZATIONS PRESENT DCS PLC HybridControl Capabilities

Process I/O A A BMultivariable Regulatory Control A C BComplex Interlocking C A ASequencing B D ARecipe Handling A D ABatch Process Control B D A

User Interface:Ease of Configuration (links & displays) A C AEase of Operator Use A D AEase of Creating Custom Displays A C A

Cost:Hardware C A AInstallation A C AApplication Programming A B A

Additional Considerations:Ease of Expansion (interactive functions) A D AFlexibility A D ARedundancy A C BReliability B A AHardware Maintainability B A ASoftware Maintainability B C A

Where do we fit?

Bit Logic Solving Hybrid Continuous Algorithm

Pro

cess

Ind

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Foxboro A2 Hybrid Automati

on System

DCS

Traditional PLC

Offering

Syste

m C

om

ple

xit

yTotal I/O Quantity

Automation Architecture Migration

ProcessIndustries

HybridIndustries

DiscreteIndustries

AutomotiveAerospaceMachining

PharmaceuticalFine Chemical

Food & BeverageConsumer

Packaged Goods

PetrochemicalRefiningPower

Pulp & Paper

ABB Emerson

HoneywellInvensysSiemens

Yokogawa

MitsubishiOmron

RockwellSchneiderSiemens

With Permission From ARC Advisory Group Strategies – June, 2001

HMI HMI ManufacturerManufacturer

Traditional PLC Vendor Supply Model

SoftwareDrivePLC

MotionSensor

OEMSystem IntegratorEngineering Contractor

Implementer Distributor

End UserBuys from: …AND …Indirectly From Suppliers:

Component Manufacturer(s)

DistributorsValue Added ResellersManufacturers Representatives

System Integrator

EngineeringContractor

Traditional DCS Vendor Supply Model

End User

Capabilities System design IT integration Process

optimization Performance

guarantees Single Source

Supply Global support

DCS DCS ManufacturerManufacturer

Buys from: …OR …Directly From Supplier:

Services Project

Management Engineering Field services Technical call

in Consulting

Platform

SoftwareControl

I/O

Combined Systems vs Hybrid Systems

PLC and HMI System Hybrid Control System

Components function/scope not coordinated

Components function/scope coordinated

Function extensions in components for system performance

System functions are included in individual components

Frequently from various suppliers From a single source

Integration work necessary Integrated overall system

Product competence Application/system competence

Individual product responsibility System responsibility

Individually optimized components

Optimally coordinated system

Innovation cycles not coordinated Innovations coordinated

• Uniformity not ensured

• Additional effort by user

High integration effort

• Uniform functions• System

performance without additional effort

Alarms / messagesDiagnosis

RedundancyDocumentationAccess rights

Customer Support

Implementation effort

PLC and HMI System Hybrid Control System

System costs System hardware System software

Engineering and startup System-wide configuring tools Integration support

Maintenance costs Integrated service concept Adapted versions

Expansion costs Homogeneous configuring landscape Up-to-date documentation Scalable system hardware

Engineering

Maintenance

Expansion

HW/SW components

Hybrid process control system

Combined System from various manufacturers

Investment in system performance is more than compensated through savings in engineering!

Economical over entire life cycle (total cost of ownership )

Engineering

Maintenance

Expansion

HW/SW components

ArchestrA Framework

Visualize• Current

status• Monitor

Analyze• Problems• Find

opportunities

Optimize• Spread best practices• Adjust process & procedures

Sustainable Integration

Today’s Islands of A

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Utilities

IntelligentEquipment

Processing

Inventory

Collaboration

• ArchestrA is an innovative technology that is focused on collaboration in the design, use and maintenance of plant automation

• ArchestrA uniquely normalizes diverse sources of data into a secure, object-based environment.

• ArchestrA has a library of over 1,000 programmable plant floor devices

• ArchestrA uniquely enables adaptive security for central or remote control rooms

Homeland Security for Drinking Water Supplies

Three Areas– Increased physical security surrounding water supply

systems– Redundancy design in the system– Source water protection and monitoring

“Homeland Security for Drinking Water Supplies”

The most expedient and potentially less costly actions for protecting a water supply system consist of installing or enhancing a physical security system, including fences, exterior and interior sensors, alarm assessment and communication and entry control. The risk of cyber threat can be reduced by increasing security in the Supervisory Control and Data Acquisition (SCADA) System used for utility monitoring and operation and remote communication. SCADA security can be tightened by either hardware or software enhancements by IT professionals.

» Marcia Greenblatt, Ph.D., Jack Donohue, and Ken Wagner Ph.D.Courtesy of ENSR International

Translation: Control system design consideration other than adequacy of meeting control needs.

“Homeland Security for Drinking Water Supplies”

Source water protection and early warning monitoring systems could alert operators of any change in water quality in sufficient time to prevent contamination and disruption of the public water supply. Early water monitoring requires a long-term baseline of water quality data to understand typical parameter ranges. When observed water quality parameters are outside expected values, warning signals can be transmitted, increased sampling and testing can be conducted, and the system operation adjusted appropriately. In addition to a well designed monitoring system, an inventory of system hydrology (including reservoir residence times, dilution rates, flow-stage relationships, etc.) will allow for rapid assessment and decision making in the event of contamination.

» Marcia Greenblatt, Ph.D., Jack Donohue, and Ken Wagner Ph.D.Courtesy of ENSR International

Translation: You cannot control what you cannot measure!!

Simple solutions for security Prepare (or update) an emergency response plan. Make sure all employees

help to create it and receive training on the plan Post updates emergency 24-hour numbers at your facilities in highly visible

areas (pump house door, vehicles, office) and give them to key personnel and local response officials

Get to know your local police and ask them to add your facilities to their routine rounds. Practice emergency response and public health officials

Fence and lock your drinking water facilities and vulnerable areas (e.g. wellhead, hydrants, manholes, pump house, and storage tanks)

Lock all entry gates and doors and set alarms to indicate illegal entry. Do not leave keys in equipment or vehicles at any time

Install good lighting around your pump house, treatment facility and parking lot

Identify existing and alternate water supplies and maximize use of back flow prevention devices and interconnections

Use your Source Water Assessment information to work with any businesses and homeowners that are listed as potential sources of contamination and lesson their threat to your sources

Lock monitoring wells to prevent vandals or terrorists from pouring contaminants directly into ground water near your source. Prevent pouring or siphoning contaminants through vent pipes by moving them inside the pump house or treatment plants, or if that isn't possible, fencing or screening them

In case of an emergency, first call "911", then follow your emergency response plan– From: EPA New England Office

Foxboro A2 answers “Call to Duty”

Control System Security – 21 CFR Part 11 compliance– Control Variables Secured– Network Secured– Historical Records Secured

Physical Security– Limit switches on doors, fences, and gates integrated

into control system – industry domain expertise– Live video feeds from critical points and integrated

into control system Accurate Control system data locked into secured

database

Invensys Newsletter Link

http://www.foxboro-newsletters.com/Insights0405int.htm– AWWA Interim Voluntary Security Guidance for

Wastewater/Stormwater Utilities – Chapter 5 Cyber Security

– Pretreatment and Effluent EPA Guidelines– Case Studies

Conclusion

Discussion of DCS, PLC, SCADA, and Hybrid control systems– Definitions and advantages

Markets served by various technologies– Technologies to appropriate industries

Hybrid control system advantages in Water and Waste Water– Technological advantages of all rolled into one

Technology Future of Invensys – setting the pace for automation industry– AchestrA – all elements of plant working in concert

Homeland Security– Actions and control system complements

Questions and Comments