Details withheld at reviewer request. Product name and version: FactoryTalk View Supervisory Edition 6.1

Transcription

1 Rockwell Automation End-user details Name: Details withheld at reviewer request SI details Name: Ivan Slabbert Designation: Project Engineer Company: Staro Process Control Phone: +27 (0) Product details Product name and version: FactoryTalk View Supervisory Edition 6.1 Vendor: Rockwell Automation Phone: +27 (0) URL: Application details Location: Alberton, Gauteng, South Africa Industry: Oil and gas Date project started: Date project completed: Application: Fuel storage and transfer Server OS: Windows Server 2008 R2 Standard Client OS: Windows 7 Pro 64-bit Application statistics Tag count: Hardwired I/O = 639 Modbus I/O = 2906 Updates per day: N/A Disk space for one day s updates: N/A Physical I/O count: Copyright Technews Publishing (Pty) Ltd All rights reserved

2 Front ends: Licences: 2 * AllenBradley ControlLogix Process Automation Controllers (Common Industrial Protocol 0 CIP) 1 * Emerson Raptor Tank Level Gauging (Modbus RTU) 7 * Loading Bay Controller systems (Modbus TCP) 2 * Compressor systems (Modbus RTU) 1 * Generator (Modbus RTU) 1 * HIMA Emergency Shutdown System (Modbus TCP) 1 * ABB MCC (Modbus RTU) 2 * Emerson Coriolis flow transmitters (Modbus RTU) 1 * BEKA intrinsic safe operator display (Modbus RTU) 4 * ABB Medium Voltage Circuit Breakers (Modbus TCP) 1 * FactoryTalk View SE Server 2 * FactoryTalk View SE Client 1 * FactoryTalk View SE Studio 1 * FactoryTalk Gateway 2014 Copyright Technews Publishing (Pty) Ltd All rights reserved

3 End user responses General Q: Briefly describe the application including information on any pre-existing control system. The bulk fuel storage utility consists of fuel storage tanks, incoming pipeline connections and a loading gantry. A new plant was built to replace the existing plant, which was manually operated. The new plant was to be automated to the extent of integrating most equipment into one comprehensive control system. Q: What was the primary motivation for the project? To operate a new fuel storage utility, where capacity is more than doubled, with the same headcount as the old utility. Q: What were the main goals established for the project? To implement the Buncefield recommendations for fuel storage utilities. To upgrade the fuel tanks to comply with regulations. To increase storage capacity. To increase the throughput of the facility. To improve the accounting in the fuel depot. Q: In the procurement decision making process what were the primary considerations that influenced the product selection? Ease of use, support from vendor and provision for future expansion. Q: What Project Management principles and/or methodologies did you employ as end-user to mitigate risk, ensuring the project came out on time and within budget? Risk mitigation: Perform Hazop studies. From Hazop studies, do Safety Integrity Level (SIL) studies. From the above, generate the elements of risk that should be mitigated. Schedule management: Used the standard Critical Path Method (CPM) to identify critical activities and spend more resources on them Copyright Technews Publishing (Pty) Ltd All rights reserved

4 In implementing the CPM method, the Precedence Diagramming Method (PDM) was used. Budgetary control: Minimised rework by performing Factory Acceptance Tests (FATs) before the equipment was delivered to site and Site Acceptance Tests (SATs) after delivery. Licensing, maintenance & support Q: What upgrade agreements are in place for this application? Rockwell Automation TechConnect support and engineering and maintenance support. Q: How is after-sales support handled on this application? Up until now, after-sales support was done on a call-out basis. In the near future it will be included in the engineering and maintenance support contract. Q: Do you have a documented process in place to manage, test and install OS and scada system software patches? Architecture, integration, reporting and archiving Q: Is the scada system integrated onto an intranet or the Internet? The scada system is installed on a dedicated plant Ethernet network. Q: Does the system include or interface with an expert system? Q: Does the system include any form of augmented cognition (AC) or augmented reality (AR)? Q: Is the system integrated with an MES / ERP or other management reporting or control system? Q: Has any GIS (Geographic Information Systems) functionality been configured in the application? 2014 Copyright Technews Publishing (Pty) Ltd All rights reserved

5 Q: Has any asset management functionality been configured in the application (for software assets, control system assets or for plant assets)? Q: Do you run the scada in conjunction with any other third-party application software? Q: Does the application include data archiving / historian capabilities with an historical data reporting system? Q: Have any production benchmarking tools been configured as part of the scada system? Mobile device support Q: Are you currently using tablets, mobile phones or other smart mobile devices to interact with the scada system? Q: Do you allow users to interface with the scada system via their own personal smart devices? (BYOD) End-user conclusion Q: What was the predominant feature (or features) that made you decide to purchase this scada product over all others for this application? The scada system was bundled with the installation of the process automation controllers for the fuel storage utility. Q: What was the most significant change that you implemented in scada engineering practice / technology in this project? None Copyright Technews Publishing (Pty) Ltd All rights reserved

6 Q: What single operational feature most impresses you about the product now that it is in operation? Ease of use of the system. An example is the simplification of receiving fuel via pipeline to the storage tanks. Q: What impresses you most about the architecture? No response Copyright Technews Publishing (Pty) Ltd All rights reserved

7 SI Responses Project details Q: What tools were used to minimise the man-hours taken? Man-hours on scada configuration were minimized by making use of Global Objects (re-usable graphic objects) that are linked to matching logic blocks in the Process Automation Controller. Each object type has a global object graphic symbol which is placed on the scada graphic display. For example a valve global object symbol is linked to a valve s tag structure in the controller, which will pass information such as open / closed status, fault status, name and description to the scada. When clicking on the symbol, a generic valve faceplate is opened from which detail status (such as interlocks), manual control and configuration are accessible. When using this concept, scada configuration time is greatly reduced as objects are linked (pumps, valves, analog transmitters) instead of their individual tags. Q: Do the operator interfaces on this project use multi-touch gestures? Q: What human factors were taken into consideration as principles or development standards in the HMI design process? Navigation principles similar to web browsing were followed, as operators are well acquainted with it. Process pipelines can be followed by clicking hyperlinks, navigating to the next corresponding process display. A two-click principle was followed where an operator should be able to navigate to any section of the scada within two clicks. This was accomplished with a two-level menu system, where the top bar navigates to a section, and the bottom bar navigates to the scada display. The Abnormal Situation Management Consortium s (ASMC) guidelines for effective control were followed to ensure effective operator display design. This includes factors such as: Colour schemes: All normal process activity is displayed in different scales of grey. While this efficiently communicates normal process data to the operator, it is not distractive, and allows abnormal situations to be highlighted by making use of coloured borders and alarm symbols. Alarm management: Alarms were divided into three priority groups, each with a separate colour and alarm symbol. Critical alarms are displayed in red, high priority alarms in amber, 2014 Copyright Technews Publishing (Pty) Ltd All rights reserved

8 and low priority alarms in light blue. Unacknowledged alarms are indicated with a flashing border, where acknowledged alarms have a solid border. Q: For the graphics development process did you use standard library images, or did you have to draw images from scratch? All images were developed from scratch to comply with the ASMC guidelines. Q: How would you describe the library of graphic images? FactoryTalk View SE has a comprehensive image library. Q: Did you use any special images? Q: Did you use any video or multimedia technology in the application? No multimedia were embedded in the application, but PDF documents were integrated into the scada application to give access to tank volume strapping tables without having to switch to a different application. Q: What alarm management standards or best practices were adopted in configuring the scada system alarms? Followed the ASMC guidelines for effective operator display design. Q: What structured processes were followed to determine expected performance under full load, and during abnormal failure conditions? Followed vendor recommended hardware and software requirements. Q: What are the key physical communication layers and communication protocols employed in the system? Ethernet, single mode fibre, Modbus RTU (via Modbus TCP/RTU gateways). Q: What is the network speed and communications medium of the slowest link in this project s scada network? 100Mbit/s over CAT5 copper. Q: What is the network speed and communications medium of the fastest link in this project s scada network? 1Gbit/s over single mode fibre Copyright Technews Publishing (Pty) Ltd All rights reserved

9 Q: What levels of redundancy are incorporated in this scada application? Network redundancy was incorporated by means of a Rapid Spanning Tree Ethernet ring. Q: What specific custom code or scada scripts were written for this project? None. Project management Q: What Project Management principles and/or methodologies did you as SI employ to mitigate risk and to ensure the project came out on time and within budget? No response. Security and data protection Q: How have authentication, authorisation and role management been configured? Authentication and authorisation were configured within the application. Operator and engineering stations were locked down using Windows security policies to prevent unauthorised software from being run on these computers. As authentication and authorisation were handled within the scada application, auto-login into Windows and automatic start-up of the scada application was configured. Q: Does the design make provision for a DMZ and firewall segregation of process (scada) network and business networks? Q: What intrusion detection has been incorporated on the plant network(s) on which this scada system exists? None. Q: Is the security model employed based on a standard? Q: In what ways is this project s hardware architecture optimised for patch management and antivirus management? None. Q: What configuration back-up and data archive backup methodologies have been adopted? Configuration backups are done manually as changes are made to the system Copyright Technews Publishing (Pty) Ltd All rights reserved

10 Q: Did you use any integrated or third party configuration control system for the scada configuration during the engineering of this application? SI conclusion Q: What impresses you most about the architecture? The powerful alarming architecture that is available in FactoryTalk View SE when using ControlLogix controllers makes alarm configuration very simple. Alarms are configured in the controller (can be done from a scada faceplate), and the scada server subscribes to the alarms automatically. String tags can be passed to the alarm instructions in the controller, giving the possibility of creating dynamic alarms that adapt with process conditions or operator input. (The operator can for example change the description of an instrument {stored as a string value in the controller}, which will automatically update the alarm s description as well.) Q: What impresses you the most about the engineering / configuration aspects of the product now that it is in operation? The strong integration between FactoryTalk View and AllenBradly ControlLogix controllers when making use of controller add-on instructions and user defined types in conjunction with scada global objects and faceplates. This gives a uniform operator interface which is easy to learn. Operator training requirements were greatly reduced because of this. Q: How would you rate the ease of use of the historical reporting system? N/A Copyright Technews Publishing (Pty) Ltd All rights reserved

11 Vendor responses Product Product version / Module versions Current version Factory Talk View SE Station ver 7.0 Subject project - used FactoryTalk View SE Station ver 6.1 Q: Vendor comments on product / modules? The product provides site-level visualization, and is available in 15, 25, 100, 250 and unlimited display licences. The solution is scalable from a single station to distributed applications. It supports redundant alarm, data and HMI servers. Architectural components of FactoryTalk View Site Edition include: FactoryTalk View Studio: for configuration, development and testing HMI applications. FactoryTalk View Site Edition Server: an HMI server that stores such project components as graphic displays and tags and serves these components to clients. FactoryTalk View Site Edition Client: client software for viewing and interacting with site level applications developed using FactoryTalk View Studio. FactoryTalk View Site Edition Station (Local): a stand-alone HMI solution that packages a Server and Client for use on a single computer FactoryTalk ViewPoint: an HMI add-on that extends access for both FactoryTalk View Machine Edition and Site Edition to a web browser. FactoryTalk View Site Edition Station (Network Station) FactoryTalk View SE provides server redundancy for FactoryTalk Alarms and Events, giving reliable visibility into critical conditions that require immediate action. In addition to alarms and events, FactoryTalk View SE subscribes to shared security functionality that further improves control over plant-floor activities. For critical operations like setpoint changes or recipe downloads, the system requires user verification. All activity is then logged through FactoryTalk Diagnostics, a consistent protocol for storing and managing activity, status, warnings and activities throughout the FactoryTalk platform Copyright Technews Publishing (Pty) Ltd All rights reserved

12 Operating systems / VMware Product response - supported Windows Vista Business SP1 32-bit Windows Vista Business 32-bit Windows 7 Enterprise SP1 64- bit Windows 7 Enterprise SP1 32- Operating systems client side bit run-time? Windows 7 Professional SP1 64-bit Windows 7 Professional SP1 32-bit Windows 7 Professional 64-bit Windows 7 Professional 32-bit Windows 7 Ultimate SP1 64-bit Operating systems client side As above configuration? All Rockwell Automation device protocols Operating systems server OPC side? Modbus Many Kepware protocols Subject project - used Windows 7 Pro 64-bit Windows 7 Pro 64-bit Modbus TCP/IP Modbus RTU OPC 2014 Copyright Technews Publishing (Pty) Ltd All rights reserved

13 Does the scada system rely on Java plug-ins to exploit the full functionality of its core and additional modules? No No Q: Vendor comments on operating systems The FactoryTalk ViewPoint client can only be hosted on devices that provide "in-browser" Silverlight support. This precludes the use of mobile devices (ios- and Android-based phones and tablets). Future web clients based on HTML5 rather than Silverlight will overcome this restriction. The FactoryTalk VantagePoint Mobile app is made to work natively for Windows 8.1, taking advantage of the new features in Microsoft's latest operating system update. Within the app, users can view key performance indicators (KPIs), operational equipment effectiveness (OEE), or mean time between failure/-to repair (MTBF/MTTR) values. Detailed reports and trends can be accessed via the KPI gauge or charts. Licensing, maintenance & support model Q: What sort of licensing agreement options are offered? Each separate product has its own licence creating a modular structure. For the scada Server / Client product, the licences are laid out as follows: HMI server 25, 100, 250 and unlimited display licence (The scada is licensed per developed display, and not per tag as other products traditionally are). The Clients are licensed individually and can be either full or read only licences. For the standalone versions of the scada software (FactoryTalk View Station) the licences come in the same display sets (i.e. 25, 100, 250 and unlimited). All scada licences include the same functionality and are only limited on the amount of displays that can be created. Q: Are licences sold outright or subject to periodic (e.g. annual) renewal? All licences are sold outright Copyright Technews Publishing (Pty) Ltd All rights reserved

14 Q: What upgrade agreements are offered? As part of the TechConnect Contract after sales support annual agreement all patch updates and software upgrades are free. Access to the knowledge base carrying information on all products, applications, patches and upgrades is also included. Q: What after-sales offerings iro support and maintenance are available, and which technologies are used to deliver them? Options are available covering self-assist support, product support, system support and application support. The Virtual Support Engineer offering is a service that offers an easy, scalable and cost-effective solution for remote support via a small, DIN rail device and remotely configured interface. Q: Do you have a documented process in place to manage and test OS patches and to release scada system software patches? Microsoft releases a range of security updates, operating system and other software updates. Rockwell Automation qualifies certain Microsoft updates for software that impacts Rockwell Automation software products. It is recommended that end-users implement a controlled system suitable for their application and environment, and follow the guidance below for the distribution of all updates. It is strongly recommended that Microsoft updates are not applied or installed until (i) (ii) The MS update has been Fully Qualified by Rockwell Automation The results of our testing have been published and reviewed. Fully Qualified means that Rockwell Automation has tested the MS updates with the primary functional areas of the relevant Rockwell Software products. When completed, test results that show the areas tested will be posted for end-user review. Rockwell qualifies MS updates for the Microsoft operating systems, MS Offices Products, Internet Explorer and MS SQL Server products within a short period of time of the release of the MS update but will generally qualify MS updates denoted as Critical with first testing priority. Rockwell scada related patches are delivered by means of the Knowledgebase. The FactoryTalk View patch roll-up is updated monthly as well as with the latest releases of the products Copyright Technews Publishing (Pty) Ltd All rights reserved

15 Attached to the Technote is a batch file (for automated installation) as well as the patch installation procedure for servers and client machines, as well as a downloadable file containing the patches. It is always recommended that the patches be rolled-out on a test system to check for any conflicts before loading to the main system. Technology incorporated Product response Subject project Product uses Web Services? FactoryTalk ViewPoint No Cloud computing supported? No No Virtualisation models VMware No supported? Multi-touch gestures supported by OS + scada hardware + scada software? No No Q: What changes have been introduced into the product in the last 12 months? The following new features have been introduced in the last year s update: Network View SE Station increasing the integration into the information layer. TrendX support for FactoryTalk Historian ME increasing the integration into the information layer. FactoryTalk VantagePoint Trend Active X support increasing the integration into the information layer. Expanded System Topology Limits for process industry support. ISA 18.2 Alarming Standard support for Shelving State for process industry support. Remote Tag Based Alarming Commands for process industry support. Cross Reference / Find and Replace in View Studio increasing usability. Gradient Shading and PNG Support increasing usability. Integration and reporting Q: What generic and/or product specific interfaces does the product have iro well-known MES packages? FactoryTalk VantagePoint EMI enables individuals to view web-based reports and KPI dashboards and provides a gateway through which manufacturing data may be accessed Copyright Technews Publishing (Pty) Ltd All rights reserved

16 VantagePoint reporting content can be made available ass Web Parts on a SharePoint page leveraging other collaboration tools from Microsoft such as Excel. Q: What native historical data reporting options are available? The only MES product that has a SAP connector is FactoryTalk VantagePoint EMI reporting package. PLC configuration and programming Q: What capabilities does the scada offer in terms of generation and/or management of PLC configuration files or PLC application code? The FactoryTalk View SE product range does not offer any tools in terms of PLC code generation. Security and data protection Q: If the scada system generates application files that are transferred to the PLC, how are PLC virus attacks prevented in this process? N/A. Q: What authentication, authorisation & role management models are available for the runtime environment? As part of the FactoryTalk Platform all Rockwell Automation software products use the same 2014 Copyright Technews Publishing (Pty) Ltd All rights reserved

17 Cross Reference / Find and Replace at design time ISA 18.2 Alarming Standard support for shelving state Design time productivity Process industry support through use of Industry Standards 2014 Copyright Technews Publishing (Pty) Ltd All rights reserved