New SCADA Technologies and Making Data Available from the Shop Floor Nick Toussaint, PE, PMP September 22, 2015

Objectives What is SCADA Review SCADA Architectures Providing Information to Users Security SCADA Life and Upgrades Total Cost of Ownership Using Open Source Technologies

SCADA Definition •

SCADA - Supervisory Control and Data Acquisition – Usually people consider the computer the SCADA system, but it’s the whole system – There is an assumption that there is local control and logic processing – Process control continues even if SCADA computer is down

SCADA  Computer

Setpoints

Operator Interface Process Data

Logic Processing

I/O

Figure 1 – Single Node SCADA Architecture

Single Site - Standard Single Node Architecture •

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All equipment located at a single site except for remote client One Server License is required Depending on vendor, additional clients can cost from $500 - $2000 Databases can add $1000s or more to project cost

Multiple Site - Standard Single Node Architecture •

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One SCADA node, with other PLCs and clients at different sites One Server License is required Can view data on any site from any site Data loss if network goes down

Multiple Site – Multi Node Architecture

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•

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SCADA node at each site Three Server Licenses are required Can view data on any site from any site No data loss if network goes down

Hub & Spoke Architecture

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SCADA node at each site (lite version at the remote sites) Three Server Licenses are required No data loss if telemetry goes down (store & forward) All Data Replicated to a database at hub

Multiple Site – Multi Node With Central Historian • • • •

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SCADA node at each site Three Server Licenses are required Can view data on any site from any site No data loss if network goes down (store & forward) All Data Replicated to a central database

Providing Data Outside the Process • Data exchange protocols make it easier to share data • Software and interfaces are easier to implement Yesterday – Interfaces (flat file exchange) Today – Database access and XML Today – Data providers (EDI) & Web Services

Providing Data Outside the Process •

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Data Communications getting more “StandAlone” Don’t have to move all data through the plant SCADA Make the data available to any user’s device Provide “Actionable” information, not just data

Security • The more you share data, the bigger the security concern becomes • Conduct a baseline security audit • Network Architecture and encryption become important assets

Sharing Data •

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Before, the cost of providing additional client licenses becomes costly, thus most plant data was not shared outside the plant, or the operations staff must export out data to allow sharing it with other departments in the organization Now, new SCADA software technologies do not limit the number of client licenses, so that data can be shared with anyone in the organization, without cost to process or view

SCADA Life • Many Plants are designed for 20 or 30 year life • How long does a computer last? (Ans:3-4 years) • How long does an OS last? ( ~5 years) • You must keep SCADA SW maintenance contracts in place in order to keep your system operating over many years & Multiple OS’s • Operating system upgrades and security patches are a big risk to operations

Total Cost of Ownership •

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With SW support costs, the Total cost of ownership goes over multiple years The total cost is the initial sw cost plus the annual support costs Support costs usually run 1520% of SW cost, but some vendors offer a lower cost

Single Node, 25 screen  license Single Node, 100 screen  license Two nodes, 3 clients

Vendor A

Vendor B

Vendor C

$      3,000 

$      12,000  $      2,600 

$      6,000  $      7,500 

$      15,000  $      2,600  $      18,000  $      3,100 

One year Support Single Node, 25 screen  license Single Node, 100 screen  license

$    540.00 

$         2,160  $          260 

$ 1,080.00 

$         2,700  $          260 

Two nodes, 3 clients

$ 1,350.00 

$         3,240  $          310 

TCO ‐ 10 yr cost (SW + Support) Single Node, 25 screen  license Single Node, 100 screen  license

$   8,400.0 

$   33,600.0  $   5,200.0 

$ 16,800.0 

$   42,000.0  $   5,200.0 

Two nodes, 3 clients

$ 21,000.0 

$   50,400.0  $   6,200.0 

Using Open Source Technologies • Using open source technologies can significantly reduce the cost of ownership • A standard database license runs $3000-$5000 initially, plus support costs • Open source version is free • Not all SCADA vendors allow use of multiple database vendors, as they SW is tied to a particular DB technology • Some commercial SW has limitations on the database size, so make sure your system can store adequate years of process data

Questions?

Energy Management System Architecture Corporate Energy Views Energy Manger Application Server Energy Management Database Server Corporate Network

Energy data replicated from local plant sites to corporate database

Wide Area Network

Local Plant Network

Energy Manger Application Server

Local Energy Views

Typical Plant Control System Layout Plant Historian

Energy Management Database Server

Isolated Plant Control Network

Energy data collected from new gas and electric meters/ submeters and stored in local plant data historians

PLC

PLC

NG F

New metering equipment

HMI

KW

F

NEW 10.x.x.x Network

Domain Controller

Backup Server

File Server

Remote WAN Router A

CURRENT 166.92.0.0 Network

LEVEL 4

MPLS NETWORK

Layer 3 Switch with Access Lists between VLAN’s

Users

Denver WAN Router

Remote WAN Router B

NEW 10.x.x.x Network NEW 10.200.x.x Network

LEVEL 3.5 E-Server/ PortalWeb

Field Device Manager

Digital Video Manager

Historian

SITE.PCN Domain Controller

IT Services: SMS, patch, antivirus, NETIQ, etc.

IT Services

CollectorPR

LEVEL 3

xMII/MES

EMS

RSLinx Professional Proficy Historian Collector

LEGACY CollectorPR 10.254.x.x RSLinx Professional Proficy Historian Collector Network

CollectorPR RSLinx Professional Proficy Historian Collector

Historian Servers

Flaw Legacy SITE.PCN Operator PKS Domain Stations Servers Detection OPC Server Server Controller

QCS TS

LEVEL 2

PKS SERVERS

All Traffic will go through Legacy OPC Server between lines

LEGACY 192.168.200.x Network A-B PLC 5

LEVEL 1 C200 Controllers

RSSQL

Terminal Server

PM FAMILY

FSC

Ethernet Field Bus Etc

NIM

New PCN Infrastructure Architecture

Operator Stations

A-B PLC 5

Historian Servers

A-B PLC 5

LEGACY 192.168.120.x Network Controllers

NEW Engineering Administrative VLAN

Note: See Page 2 for High-Level Summary and General Explanation See Page 3 for Technical Details

SITE.PCN (Process Control Network) DOMAIN

Developing an Energy Management Strategy ANSI/MSE 2000 Section Requirements

Plan/Policies

•Create Org Structure

•Develop Energy Profile

•Create Energy Strategy

•Utility Tracking

Energy Planning

•Establish KPIs •Establish Energy Goals

•Conduct Preliminary Audits

Current Level Metering

Checking/Review

•Establish Energy Policy

•Monitoring

•Implementation & Operation •Project Prioritization

•Audit •Corrective Action •KPI Adjustments

•Training & Awareness

•Establish Docs

Define

Implementation

Measure

Analyze

Improve

Control

Metering & Monitoring Are Critical To Move Beyond Requirements/Define Stage