IEEE PES Meeting

Marc L. Hunter
Foxboro A2 Automation Platform Business Manager
North 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 Hybrid
Control Capabilities
Process I/O A A B
Multivariable Regulatory Control A C B
Complex Interlocking C A A
Sequencing B D A
Recipe Handling A D A
Batch Process Control B D A
User Interface:
Ease of Configuration (links & displays) A C A
Ease of Operator Use A D A
Ease of Creating Custom Displays A C A
Cost:
Hardware C A A
Installation A C A
Application Programming A B A
Additional Considerations:
Ease of Expansion (interactive functions) A D A
Flexibility A D A
Redundancy A C B
Reliability B A A
Hardware Maintainability B A A
Software Maintainability B C A
 Where do we fit?
Total I/O Quantity

Process Industry Bit Logic Solving Hybrid Continuous Algorithm

DCS
System Complexity

Foxboro A2
Hybrid
Automation
Discrete Industry

Traditional System
PLC
Offering
 Automation Architecture Migration

Process Hybrid Discrete

Industries Industries Industries
ABB
Mitsubishi
Emerson
Omron
Honeywell Petrochemical Pharmaceutical Automotive
Refining Fine Chemical Aerospace Rockwell
Invensys Power Food & Beverage Machining Schneider
Siemens Pulp & Paper Consumer
Packaged Goods Siemens
Yokogawa

With Permission From ARC Advisory Group Strategies – June, 2001

 Traditional PLC Vendor Supply Model

End User
Buys from: …AND …Indirectly From Suppliers:

Component
Implementer Distributor Manufacturer(s)

OEM Distributors Software

System Value Added Drive
Integrator Resellers PLC
Engineering Manufacturers Motion
Contractor Representatives Sensor

HMI Manufacturer
 Traditional DCS Vendor Supply Model

End User
Buys from: …OR …Directly From Supplier:

Capabilities DCS Manufacturer

System System design
Integrator IT integration Services
Process Project Management
Engineering optimization Engineering
Contractor Performance Field services
guarantees Technical call Platform
in Consulting Software
Single Source
Control
Supply
I/O
Global support
 Combined Systems vs Hybrid Systems
PLC and HMI System Hybrid Control System
 Components function/scope not  Components function/scope
coordinated coordinated

 Function extensions in components for  System functions are included in

system performance 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

 Implementation effort

PLC and HMI System Hybrid Control System

Alarms / messages
Diagnosis
Redundancy
Documentation
Access rights
Customer Support

• Uniformity not • Uniform functions

ensured • System performance
• Additional effort without additional
by user effort
High integration effort
 Economical over entire life cycle
(total cost of ownership )
Combined System Hybrid
from various manufacturers process control system

Expansion costs
 Homogeneous configuring
landscape
 Up-to-date documentation
 Scalable system hardware
Expansion Expansion
Maintenance costs
 Integrated service concept
 Adapted versions
Maintenance Maintenance
Engineering and startup
 System-wide configuring tools
 Integration support
Engineering Engineering
System costs
HW/SW  System hardware HW/SW
components  System software components

Investment in system performance is more than

compensated through savings in engineering!
 ArchestrA Framework

Visualize
Analyze
• Current status
• Problems
• Monitor
• Find
opportunities

Optimize
• Spread best practices
• Adjust process & procedures
 Sustainable Integration

• 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
Invensys

Palletizing
1,000 programmable plant
Honeywell

floor devices
Bottling
Rockwell
Siemens

• ArchestrA uniquely enables

Labeling
Yokogawa
Emerson

Inventory adaptive security for central or

Schneider

Filling

remote control rooms

Batching

Processing
ABB

Utilities

Collaboration

Intelligent
Equipment
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