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Invensys Operations Management PBPC234 - PAC Securing Critical Data

Invensys Operations Management PBPC234 - PAC Securing Critical Data. Jamie Stapleton Technical Product Portfolio Manager November, 2011. Agenda. Introduction Where does PAC fit in the Infusion ECS Markets and Requirements What are the problems with loss of data?

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Invensys Operations Management PBPC234 - PAC Securing Critical Data

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  1. Invensys Operations ManagementPBPC234 - PAC Securing Critical Data Jamie Stapleton Technical Product Portfolio Manager November, 2011

  2. Agenda • Introduction • Where does PAC fit in the Infusion ECS • Markets and Requirements • What are the problems with loss of data? • Wonderware Historian strengths • Store and Forward extension to the point of measurement • How to set up this service? • Does this resolve the market problems? • Q&A

  3. Introduction Foxboro PAC

  4. Invensys Enterprise Control Offerings Corporate Systems Industry Solutions Services: Consulting, Project Execution, Learning, Operational Improvement, Maintenance & Support Partner Ecosystem Corporate Software Applications Invensys and Third Party Manufacturing / Production Operations Automation Invensys and Third Party Enterprise Control System IT Platform Integration and Collaboration Platform

  5. PAC, SCADA and Enterprise Control Execution Integration & Collaboration Platform Enterprise Asset Management Mobile Workforce Management Manufacturing Execution Systems Batch Performance Software Applications Enterprise Manufacturing Intelligence Performance Measurement and Reporting Asset Performance Enterprise Integration Visualization Quality Optimization Workflow Advanced Process Control Simulation / Optimization Design Operator Training Third-Party Offerings Open Device Integration Web Portal Control DCS PAC SCADA HMI Automation Software Applications Application Toolkit Safety Turbomachinery Control Safety Instrumented Systems General Purpose Safety Historian Measurement & Instrumentation Recorders Instrumentation Controllers

  6. It’s more than “just the hardware”. • Although the focus of this presentation is primarily about the Foxboro PAC product, it is important to keep in mind that it is the plant floor to top floor integration capabilities that can maximize the value that we can bring to a customer. From standalone control, to fully integrated systems, it’s more than just the hardware.

  7. Foxboro PAC System - Overview • Wonderware Pack Software - Enterprise wide visualization • Proven Scalable Architecture with Wonderware System platform inside • Versatile scalable suite of software tools to ease the configuration workload, with extensive object symbol libraries • Store and Forward, Historian ERP and MES connectivity • Eycon - Visual Supervisor • Panel Mounting, Touch screen, Display and Control • Alarm Management, Batch, Recipe, Setpoint programming Open communications • Auditor software - 21CFR part11 compliant access control • T2750 PAC & T2550 PAC - Programmable Automation Controller • Maximises Process up time - High Availability Processor and I/O • Redundant Continuous & Sequential control and Data Recording • Signal conditioning and Direct field connection of universal I/O • Start Small - Grow Big: Ideal for New and Retrofit Applications

  8. A2 Scalable System solutions we have today Foxboro PAC Solutions Eycon10/20 HMI Visualiser Historian HMI- Visualizer HMI- Visualizer Server T2750 (PAC) T2750 (PAC) T2750 (PAC) Control & I/O Small Systems <1000 I/O Unit Systems <250 I/O Large System & Cluster >3000 I/O

  9. Markets and Requirements Foxboro PAC

  10. Vertical Markets – Market Positioning High L E V E L O F A U T O M A T I O N Classic DCS PLC + HMI Refining Automotive Oil Chemicals Aerospace Gas Power Hybrid Markets -PAC Machine Parts Pulp & Paper Beverage Semiconductor Metals Fine Chemicals Food Water Pharmaceutical Glass Biotechnology Mining Low Scientifically-Oriented (Process) Craft-Oriented (Batch) Mechanically-Oriented (Discrete)

  11. PAC System Requirements • Hybrid Markets PAC • Single vendor • Tightly integrated • Upward scalability • Downward scalability • Built-in Redundancy • High Availability • Flexible architecture • Low Entry - scalable • Central Configuration • Prebuilt interface • Lifetime support • Local SI support • Classic DCS • Single vendor • Tightly integrated components and common platform • Good upward scalability • Poor downward scalability • Built-in Redundancy • High Availability >99.999% • Moderately flexible architecture • High Entry Cost • Central Configuration • Prebuilt Operator interface • Lifetime support • PLC + HMI • Multi vendor • Loosely integrated components , many platforms • Poor upward scalability • Good downward scalability • Custom Engineering • Normal Availability • Highly flexible architecture • Low Entry Cost • Many config environments • Custom operator displays • Local SI support

  12. Glass : Float Bottling Fibre Solar Power : Biomass Incinerators Small power plant <150MW Renewable energy Metal : Heat Treatment Target markets Target Applications • Utilities : • Burner Management • Boiler Management • Pharmaceutical : • API • EMS/BMS • Wastewater : • Municipality • Industrial • Desalination • Water Treatment

  13. What are the problems with loss of Data? Foxboro PAC

  14. Problems caused by data loss What do we mean by data loss? • Data means Process Values as well as Alarm and Events (Audit Trail) • Databases not available for asset management • Query not returning a full set of data • Following a disaster recovery, all the latest data after the daily IT backup is not available

  15. Problems caused by data loss What can be the cause of data loss? Source: Author’s estimates based on data from Safeware. The Insurance Agency Inc., “2000 Safeware Loss Study” 2001, and ONTRACK Data International, Inc., “Understanding Data Loss” 2003

  16. Problems caused by data loss • What is the cost of data loss to my company? • Cost of Data Loss • The cost of a Data Loss Event is directly related to the value of the data and the length of time that is needed, but unavailable. Consider: • The cost of continuing without the data • The cost of recreating the data • The cost of notifying users in the event of a compromise

  17. Problems caused by data loss Which risks does my company face due to data loss? Companies recognise that data loss represents a business risk. Even if a monetary value is not assigned to the data, the negative effects on operations can be significant. In many cases, corporate operations can be so adversely affected that companies feel the need to mention the risk in regulatory filings and shareholders reports. If any information is missing or not accounted for the batch will be no good

  18. Problems caused by data loss • Which risks I/my company is facing with data loss? • What can I do with my 5 M$ batch if I am missing GMP values in my records? • How I do explain to the regulatory auditor when they discover I have lost critical data, during a day on our production building? • Can I assure my company is not allowing polluted gasses in the atmosphere, in order to keep my environmental grade? • For how long have I produced out of specification water? • How quick can I assess my power consumption? • If I select a system that can minimize data loss – I want a solution that can be validated and is secure  (not based on CSV files…)!

  19. Wonderware Historian Strengths Foxboro PAC

  20. Wonderware Historian Strengths Architecture 1: Galaxy Repository Information Server (Option) Historian Server TIER 2 InTouch (TS) Operator Clients Historian Server TIER 1 Ethernet Data Network (with Firewall) Redundant (option) Application Engine 2 Redundant (option) Communication Application Engine 1 Redundant ‘Control’ Ethernet Network I/O I/O I/O I/O Node 02 Node 01 Node 03 Node 04

  21. Wonderware Historian Strengths • Wonderware solutions to minimize data loss – Historian Tiers

  22. Wonderware Historian Strengths • Wonderware solutions to minimize data loss – Platform Store and Forward

  23. Wonderware Historian Strengths • Wonderware solutions to minimize data loss – Platform Store and Forward

  24. Wonderware Historian Strengths • What’s happening if the link between the DI Object and the PLC breaks? • Data is lost

  25. Wonderware Historian Strengths Architecture 2: Galaxy Repository Information Server (Option) Historian Server TIER 2 Web Clients (Option) Engineering station with Archestra IDE + PAC configuration tools (LINtools, etc.) InTouch (TS) Operator Clients Historian Server TIER 1 Ethernet Data Network (with Firewall) Redundant (option) Application Engine 2 Redundant (option) Communication Application Engine 1 Redundant ‘Control’ Ethernet Network (ELIN – FTP – SNTP)

  26. Store and Forward Extension Foxboro PAC

  27. Store and Forward extension • Wonderware PAC Software, Foxboro PAC hardware and Eurotherm recording devices solutions to “minimise” data loss T2750 & T2550 Historian tags and Area/Alarm groups Mapping to hardware recoded tags Eycon 6000 recorders FTP / Ethernet Store and Forward extension service Wonderware Databases nanodac FTP Server

  28. Store and Forward extension • Foxboro PAC, solutions to “minimise” data loss • Simplex or Redundant Processors • Simplex or redundant data logging with Profibus & Modbus communication • 32 MB logging capacity (on board non volatile flash) • up to 3 FTP server & up to 2 SNTP server for time synchronisation • Full integration to System Platform with Wonderware PAC • 21 CFR Part 11 tamperproof records Intelligent HMI including data management • Continuous and Batch data logging with Profibus & Modbus communication • 45 MB logging capacity (on board non volatile flash) • up to 3 FTP server & up to 2 SNTP server for time synchronisation • Full integration to System Platform with Wonderware PAC • 21 CFR Part 11 tamperproof records

  29. Store and Forward extension • Foxboro PAC, solutions to minimize data loss • Simple data logger with vibrant displays • Data logging down to 125 ms • 50 MB logging capacity (on board non volatile flash) • 21 CFR Part 11 tamperproof records • Perfect for OEM integration Data logger with HMI • Data logging down to 125 ms • Up to 96 MB logging capacity (on board non volatile flash) • 21 CFR Part 11 tamperproof records • Active Directory connectivity for user management • Continuous and Batch data logging with Modbus communication

  30. Store and Forward extension • Store and Forward Extension solution to minimize data loss • Secure local historian files: • Tamperproof files • Checksum verification for corruption • Encryption • Contains time stampedprocess values • Contains time stamped Alarms and events • 21CFR Part11 compliant • Backward compatible for 20 years • ODBC interface (Data Secure ODBC)

  31. Store and Forward extension • Store and Forward Extension solution to minimize data loss • When new hardware data set is available: • Query Historian server for data gaps • Update its analysis context and log files • Fill in Historian with the missing data • Secure writes to Historian API • Fill in Alarm history database • Secure writes to Alarm DB logger • Run as a service • Uses service networks accounts Historian tags and Area/Alarm groups Mapping to hardware recoded tags Store and Forward extension service

  32. Store and Forward extension • Store and Forward Extension solution to minimize data loss • Compliancy: • Windows 32bit OS (XP, 2003 Server) • Wonderware Historian 9 & 10 • System Platform 4.0 • Uses standard IIS FTP server • Works at UTC Time stamp level • Future (Q4) • Windows 7 (32 & 64bit), 2008 Server Historian tags and Area/Alarm groups Mapping to hardware recoded tags Store and Forward extension service

  33. Demo Foxboro PAC

  34. How to setup? • Configuration: • Store and Forward local database • Historian tag mapping • Area/Alarm group mapping • Context and service setup • Fill in data missing…

  35. Does this resolve the markets problems? Foxboro PAC

  36. Does this resolve the markets problems? • Point of measurement redundant logging • Redundant logging devices fit in cubicles • VxWorks Operating System (RT OS) • CPU watchdog as standard • Recorded data on non removable and high reliable flash embedded devices Source: Author’s estimates based on data from Safeware. The Insurance Agency Inc., “2000 Safeware Loss Study” 2001, and ONTRACK Data International, Inc., “Understanding Data Loss” 2003

  37. Does this resolve the markets problems? • References & major successes: GSK Ware Warehouse Monitoring system Redundant InTouch application with Historian and HMI Reports Extensions to production area at present Site Alarm Monitoring System Full Redundant System Platform application with Historian The end target is 12000 IOs Kiln Control system for Bricks manufacturing Redundant InTouch application with Historian 6 furnaces spread around two sites

  38. Questions? • SP • PAC Foxboro PAC

  39. Configuration Demonstration Foxboro PAC

  40. Thank You Hardware and Software Solutions for Real Time Success

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