IEEE PES Meeting Marc L Hunter Foxboro A

IEEE PES Meeting Marc L. Hunter Foxboro A 2 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 4 Homeland Security 4 4

Distributed Control 4 “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 4 4 4 4 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 4 “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 4 4 4 Easy to use and install Distribution network – local electrical supply house Inexpensive Electrician can diagnose and upgrade ADEQUACY

SCADA 4 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. ” 4 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 4 4 4 Integrated package – communications and control Tailored to specific application Niche market domain expertise Key attributes within communications Economical

Hybrid Control System 4 “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 4 “The power and performance of a DCS at the price and ease of use of a PLC” » Invensys Foxboro

Hybrid Control System Advantages 4 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

Where do we fit? Total I/O Quantity Process Industry Discrete Industry System Complexity Bit Logic Solving Hybrid Continuous Algorithm DCS Traditional PLC Offering Foxboro A 2 Hybrid Automation System

Automation Architecture Migration Process Industries ABB Emerson Honeywell Invensys Siemens Yokogawa Petrochemical Refining Power Pulp & Paper Hybrid Industries Pharmaceutical Fine Chemical Food & Beverage Consumer Packaged Goods Discrete Industries Automotive Aerospace Machining Mitsubishi Omron Rockwell Schneider Siemens With Permission From ARC Advisory Group Strategies – June, 2001

Traditional PLC Vendor Supply Model End User Buys from: Implementer OEM System Integrator Engineering Contractor …AND …Indirectly From Suppliers: Distributors Value Added Resellers Manufacturers Representatives HMI Manufacturer Component Manufacturer(s) Software Drive PLC Motion Sensor

Traditional DCS Vendor Supply Model End User Buys from: System Integrator Engineering Contractor …OR …Directly From Supplier: Capabilities System design IT integration Process optimization Performance guarantees Single Source Supply Global support DCS Manufacturer Services Project Management Engineering Field services Platform Technical call in Consulting Software Control I/O

Combined Systems vs Hybrid Systems PLC and HMI System Hybrid Control System 4 Components function/scope not coordinated 4 Components function/scope coordinated 4 Function extensions in components for system performance 4 System functions are included in individual components 4 Frequently from various suppliers 4 From a single source 4 Integration work necessary 4 Integrated overall system 4 Product competence 4 Application/system competence 4 Individual product responsibility 4 System responsibility 4 Individually optimized components 4 Optimally coordinated system 4 Innovation cycles not coordinated 4 Innovations coordinated

Implementation effort PLC and HMI System Hybrid Control System Alarms / messages Diagnosis Redundancy Documentation Access rights Customer Support • Uniformity not ensured • Additional effort by user High integration effort • Uniform functions • System performance without additional effort

Economical over entire life cycle (total cost of ownership ) Combined System from various manufacturers Expansion Maintenance Engineering HW/SW components Hybrid process control system Expansion costs n Homogeneous configuring landscape n Up-to-date documentation n Scalable system hardware Maintenance costs n Integrated service concept n Adapted versions Engineering and startup n System-wide configuring tools n Integration support System costs n System hardware n System software Investment in system performance is more than compensated through savings in engineering! Expansion Maintenance Engineering HW/SW components

Archestr. A Framework Visualize • Current status • Monitor Analyze • Problems • Find opportunities Optimize • Spread best practices • Adjust process & procedures

Sustainable Integration • Archestr. A is an innovative technology that is focused on collaboration in the design, use and maintenance of plant automation Palletizing Processing ’s T d an Isl A of on ti ma uto s ay od • Archestr. A has a library of over 1, 000 programmable plant floor devices Inventory Utilities Collaboration Intelligent Equipment Bottling Labeling Filling Batching ABB Schneider Emerson Yokogawa Siemens Rockwell Honeywell Invensys • Archestr. A uniquely normalizes diverse sources of data into a secure, object-based environment. • Archestr. A uniquely enables adaptive security for central or remote control rooms

Homeland Security for Drinking Water Supplies 4 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” 4 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 4 Translation: Control system design consideration other than adequacy of meeting control needs.

“Homeland Security for Drinking Water Supplies” 4 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 4 Translation: You cannot control what you cannot measure!!

Simple solutions for security 4 Prepare (or update) an emergency response plan. Make sure all employees help to create it and receive training on the plan 4 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 4 Get to know your local police and ask them to add your facilities to their routine rounds. Practice emergency response and public health officials 4 Fence and lock your drinking water facilities and vulnerable areas (e. g. wellhead, hydrants, manholes, pump house, and storage tanks) 4 Lock all entry gates and doors and set alarms to indicate illegal entry. Do not leave keys in equipment or vehicles at any time 4 Install good lighting around your pump house, treatment facility and parking lot 4 Identify existing and alternate water supplies and maximize use of back flow prevention devices and interconnections 4 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 4 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 4 In case of an emergency, first call "911", then follow your emergency response plan – From: EPA New England Office

Foxboro A 2 answers “Call to Duty” 4 Control System Security – 21 CFR Part 11 compliance – Control Variables Secured – Network Secured – Historical Records Secured 4 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 4 Accurate Control system data locked into secured database

Invensys Newsletter Link 4 http: //www. foxboro-newsletters. com/Insights 0405 int. htm – AWWA Interim Voluntary Security Guidance for Wastewater/Stormwater Utilities – Chapter 5 Cyber Security – Pretreatment and Effluent EPA Guidelines – Case Studies

Conclusion 4 Discussion of DCS, PLC, SCADA, and Hybrid control systems – Definitions and advantages 4 Markets served by various technologies – Technologies to appropriate industries 4 Hybrid control system advantages in Water and Waste Water – Technological advantages of all rolled into one 4 Technology Future of Invensys – setting the pace for automation industry – Achestr. A – all elements of plant working in concert 4 Homeland Security – Actions and control system complements

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