Minewide Convergence of Control and Information

Transcription

1 Minewide Convergence of Control and Information Pat Murray June 2010 Copyright 2009 Rockwell Automation, Inc. All rights reserved.

2 Production Management Concerns Maintaining a Safe work Environment Lack of visibility and remote management Troubleshooting and Autonomous Mining Maintaining process stability and efficiency Managing labour skill gap Reducing operating costs and TCO Managing the risk of displacing existing technology Complying with regulatory requirements

3 Innovation: IT Convergence Methodology: Reduce Cost of Ownership & IT support burden via: Integration of complementary applications Elimination of overlapping applications Trends in IT Convergence: Standards-based app integration (i.e. ISA 88/95, OPC, etc) Consolidation of disparate data models and sources Business process workflow management Current Technology Many custom applications developed over time Proprietary interfaces No overall view of Mfg landscape Labor-intensive report generation Technology Evolution Future: Enterprise & Manufacturing Integration Common data model Role-based information portals Dynamic reports not static Centralized workflow mgmt Copyright 2009 Rockwell Automation, Inc. All rights reserved. 3

4 Cultural and Organizational Convergence Security Policies IT Network Controls Network Focus Protecting Intellectual Property and Company Assets 24/7 Operations, High OEE Priorities Confidentiality Integrity Availability Availability Integrity Confidentiality Types of Data Traffic Access Control Implications of a Device Failure Threat Protection Upgrades Converged Network of Data, Voice and Video Strict Network Authentication and Access Policies Continues to Operate Shut Down Access to Detected Threat ASAP During Uptime Converged Network of Data, Control, Information, Safety and Motion Strict Physical Access Simple Network Device Access Could Stop Operation Potentially Keep Operating with a Detected Threat Scheduled During Downtime

5 IT and Manufacturing Shared Vision Ethernet to the Factory Network Management Switching Security Wireless Voice over IP Video Etc Enterprise Systems Enterprise Networks IT Domain Gigabit Backbones Self-Defending Networks Network Convergence Automation Networks Control Functionality / Real-Time Performance Safety Environmental / Form Factor Ease of Use Legacy Migration IT Compatible The Factory EtherNet/IP Standard, Unmodified Ethernet Integrated Control AND Information

6 Converged Minewide Ethernet Architectures Level 5 Level 4 Enterprise Network Router , Intranet, etc. Site Business Planning and Logistics Network Enterprise Zone Terminal Services Historian Mirror Patch Management Web Services Operations AV Server Application Server Firewall Web CIP DMZ Manufacturing reference architectures Common reference and common language for IT and manufacturing A set of tested and validated design and implementation best practices (Cisco Validated Design - CVD) Education Series Level 3 Level 2 Level 1 Level 0 FactoryTalk FactoryTalk Engineering Domain Firewall Application Directory Workstation Controller Server Site Manufacturing Operations and Control Area FactoryTalk FactoryTalk Supervisory Client Client Control Operator Engineering Operator Interface Workstation Interface Basic Control Continuous Batch Discrete Drive Safety Process Control Control Control Control Control Sensors Drives Actuators Robots Process Manufacturing Zone Cell/Area Zone With this implementation guide, for the first time IT and manufacturing professionals can share a common document for planning a converged IP network including the factory floor and automation equipment. Harry Forbes, ARC Advisory Group

7 Converged Minewide Ethernet Architectures Technology IEEE standard Ethernet, Precision Time Protocol (PTP ) n wireless (future) IETF - standard Internet Protocol (IP) ODVA - Common Industrial Protocol (CIP) IEC International Electrotechnical Commission ISA wireless (future) Manufacturing Purdue Reference Model for Control Hierarchy ISA-95 - Enterprise-Control System Integration ISA-99 - Manufacturing and Control Systems Security NIST National Institute of Standards and Technology Built on Industry Standards

8 EtherNet/IP A Single IT-friendly Network for Commercial and Industrial Applications Copyright 2009 Rockwell Automation, Inc. All rights reserved. 9 Single version of Ethernet the standard for IT and industrial applications Real-time access to power and control systems without hardware or software gateways The global standard adopted by leading automation vendors

9 Conceptual System design Level 5 Corporate ERP Zone Level 4 Mine ERP Zone Demilitarized Zone Production Zone Level 3 Mine Beneficiation Metallurgical Processing Level 2 Primary Crushing Secondary Milling Flotation Crushing Leach Plant Level 1 Cell 1 Cell 1 Cell 2 Cell 3 Cell 1 Cell 2 Process Process Process Process Process Process Level 0 Supply Chain

10 Standard Distributed System Architecture

11 Networking Power Control to Leverage Information

12 Converged Plantwide Ethernet Architectures Logical framework Industrial and IT network convergence Hierarchical segmentation Scalability Resiliency Traffic management Policy enforcement Security policies Defense in depth Secure remote access ERP, , Wide Area Network (WAN) Patch Management Terminal Services Application Mirror AV Server FactoryTalk Application Servers View Historian AssetCentre Transaction Manager FactoryTalk Services Platform Directory Security/Audit Data Servers Levels 0 2 Remote Access Server Gbps Link for Failover Detection Firewall (Active) Catalyst 6500/4500 Catalyst 3750 StackWise Switch Stack Firewall (Standby) Cisco ASA 5500 Enterprise Zone Levels 4 and 5 Demilitarized Zone (DMZ) Demilitarized Zone (DMZ) Manufacturing Zone Site Manufacturing Operations and Control Level 3 Cisco Catalyst Switch Network Services DNS, DHCP, syslog server Network and security mgmt Cell/Area Zones Drive Controller HMI DIO Cell/Area #1 Redundant Star Topology Flex Links Resiliency DIO Rockwell Automation Stratix 8000 Layer 2 Access Switch DIO HMI Drive Controller Cell/Area #2 Ring Topology Resilient Ethernet Protocol (REP) HMI DIO Cell/Area #3 Bus/Star Topology Controller Drive

13 MODE POWER STATUS ACTIVE VPN FLASH MODE SYST RPS MASTR STAT DUPLX SPEED STACK SYST RPS MASTR STAT DUPLX SPEED STACK 1X 2X 1X 2X CISCO ASA 5510 SERIES Adaptive Security Appliance X 12X 11X 12X 13X 14X 13X 14X X 24X 23X 24X Catalyst 3750 SERIES Catalyst 3750 SERIES POWER STATUS ACTIVE VPN FLASH CISCO ASA 5510 SERIES Adaptive Security Appliance Industrial Control System Secure Remote Access DMZ Cisco Adaptive Security Appliance (ASA) 5520 Firewall Manufacturing Zone FactoryTalk Application Servers View Historian AssetCentre Transaction Manager FactoryTalk Services Platform Directory Security/Audit Data Servers Cisco 3750G Stackwise Layer 3 Distribution Switch Remote Access Server Terminal Server RSLogix 5000 FactoryTalk View Studio RSLinx Classic / Enterprise Cell/Area Zones Ring Topology Stratix 8000 Rockwell Automation IE Managed Layer 2 Access Switch ControlLogix Rockwell Automation Programmable Automation Controller ICS Asset Protection Network Authorization Application Authorization Change management control Audit

14 POWER STATUS ACTIVE VPN FLASH CISCO ASA 5510 SERIES Adaptive Security Appliance Industrial Control System Secure Remote Access DMZ SSL VPN Manufacturing Zone Cell/Area Zones

15 POWER STATUS ACTIVE VPN FLASH CISCO ASA 5510 SERIES Adaptive Security Appliance Industrial Control System Secure Remote Access DMZ SSL VPN Manufacturing Zone Cell/Area Zones

16 Industrial Control System Secure Remote Access DMZ Manufacturing Zone Cell/Area Zones

17 Industrial Control System Secure Remote Access DMZ Manufacturing Zone Cell/Area Zones

18 Industrial Control System Secure Remote Access DMZ Manufacturing Zone Cell/Area Zones

19 Industrial Control System Secure Remote Access DMZ Manufacturing Zone Cell/Area Zones Industrial Control System Asset Protection Network and application authentication and authorization Change management and version control Audit and regulatory compliance

20 Innovation: Asset Utilization Methodology: Increase utilization, yields and quality via: Capturing critical plant performance data Present dashboards showing critical KPIs Identify root causes & take corrective action Trends in Asset Utilization: Role-based reports & dashboards via the web Integrate data from multiple disparate sources Real world references to data not db tables/fields Current Technology Plant performance KPIs stored to standard data model Role-based web reporting environment Drill-down reporting capability to identify root causes Technology Evolution Future: Manufacturing Intelligence Federated data model to enable site-to-site comparisons/analytics Reports publishable across the Enterprise. i.e. MS SharePoint Integration of manufacturing data with business system data Copyright 2009 Rockwell Automation, Inc. All rights reserved.

21 FactoryTalk VantagePoint Disparate Data Sources Data Connectors Data Model* Common Data Services Web Browser Data Presentation Control Systems HMI / SCADA Reports Historians Trends Maintenance X-Y Plots Laboratory Dashboards Batch OEE, Downtime, MES Custom Apps ERP Homegrown *Data organized in a meaningful way

22 Copyright 2009 Rockwell Automation, Inc. All rights reserved. 23 Unified Production Model (Common Data) Excel Trend Portal KPIs Analysis Unified Production Model Dashboards Reports RSLogix FactoryTalk FactoryTalk FactoryTalk OPC DA OPC HDA InTouch Proficy View Historian Alarms/Events Control HMI/SCADA Historians Alarms/Events RT Systems OSI PI InSQL

23 FTVantagePoint Dashboard Copyright 2009 Rockwell Automation, Inc. All rights reserved. 24

24 FTVantagePoint Dashboard Energy Copyright 2009 Rockwell Automation, Inc. All rights reserved

25 FTVantagePoint Dashboard Energy Trending Spike in Market Clearing Price of electricity Actual cost of steam More than 70 factors affect cost Copyright 2009 Rockwell Automation, Inc. All rights reserved

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27 FTVantagePoint Dashboard

28 Safety Training and certification Matrix

29 FTVantagePoint Dashboard Safety Training

30 FTVantagePoint Dashboard Safety Training

31 Information Enabled for Risk Management Logical Overview Rules The Risk Management solution offers pro-active safety and security services by utilising the intelligent network to automate disparate systems. Worker Safety Automated Procedures Audit Trail Governance & Compliance Entry Points Security Administration Zone Control Support Area Systems Control & Security Rules Exit Points Work Permits, Safety Training, Procedures etc.. Central Security Monitoring

32 Market Challenges Address Market Challenges with Convergence-Ready Solutions Copyright 2009 Rockwell Automation, Inc. All rights reserved. 33 Improve PRODUCTIVITY with better asset utilization and system performance Develop a standard set of engineering objects you can use across all of your applications Merge Promote controls with GLOBALIZATION IT to improve data with flow easy and access make faster, to actionable, smarter plant-wide business decisions information Decrease Easily downtime, extract, increase share and speed use and information simplify across integration your using enterprise intelligent and devices around the world directly Take advantage from of a single network infrastructure Cultivate manufacturing INNOVATION assets with like your increased controllers Track system your flexibility manufacturing and technical assets on risk a mitigation global basis Take advantage of a single, global standard Invest less time in development so that you can spend more time creating new intellectual property Quickly Support make SUSTAINABILITY production changes with extended to better meet market product demands lifecycles and better asset utilization Reduce waste by specifying a system in a footprint that meets your needs Reduce energy costs with by eliminating the need to over-design Streamline required assets and simultaneously reduce storage, energy costs, and waste materials

33 Real-Time Information Actionable Information Shared by Your Control and Business Systems Copyright 2009 Rockwell Automation, Inc. All rights reserved. 34 No translating or duplication necessary with live data Right data, right place, right now Improved accuracy and performance

34 Thank-you Shared Domain PEOPLE TECHNOLOGY PROCESSES & INNOVATION

35 Minewide Convergence of Control and Information Pat Murray June 2010 Copyright 2009 Rockwell Automation, Inc. All rights reserved.