Presented at the Siemens Oil & Gas Roadshow in Denver - July 2015

1. Improving and Scaling SCADA Systems:
Is WinCC OA Right for Me?
James Condon – DMC, Inc.
Unrestricted © Siemens, Inc. 2015 All rights reserved. Answers for industry.

2. Agenda
 Introduction
 WinCC Open Architecture
(OA) Overview
 Case Study Presentation
 Distributed System Project
Example
 Applying solution to O&G
 Questions

3. Presenter Info
James Condon
Project Engineer
Siemens Certified Professional
Certified WinCC OA Engineer
B.S. in Mechanical Engineering
University of Illinois in Urbana-Champaign
With DMC since 2011

4. DMC Company Profile
Industries Served:
Oil & Gas
Automotive
Chemical and Food
Processing
Electronics/Semiconductor
Hydraulics
Machine Tool
Material Handling
Metal Converting
Packaging
Pharmaceutical
Printing & Textiles
Laboratory Testing
Established in 1996, offices in Chicago, Boston, NY,
Denver, Houston & customers throughout the world
employees & growing
80+

5. Areas of Expertise

6. MANUFACTURING
AUTOMATION & INTELLIGENCE
PLC Programming
Motion Control
Engineering &
Servo Systems
HMI & SCADA
Expertise
Intelligent Data
& Web Based
Systems
Vision Inspection
Expertise
Robotics

7. TEST & MEASUREMENT AUTOMATION
NI FPGA
LabVIEW
Development
Test Stand Design
Machine Vision
Data Analysis &
Reporting
NI Real-Time

8. MICROSOFT CONSULTING SERVICES
10
10
5
5
INDIVIDUAL
CERTIFICATIONS

9. WinCC OA Introduction

10. Siemens SCADA software portfolio
WinCC Open
Architecture
WinCC V7
Standard process
visualization for
established
markets
Flexible system for software
OEMs and infrastructure
applications
Standard system for
universal use through-out
all established industries
WinCC V13
(TIA Portal)
Product for new customers
with scope on machine
level low end demand
Applicationcomplexity
Infrastructure &
Software OEMs
HMI for new
customers

11. Background
 Started in Europe
 5000 installations
all over the world
 Entered into US market
~ 4 years ago
WinCC OA

12. WinCC OA
(Open
Architecture)
 Distributed, redundancy
requirements
 Easily scalable - proper designs
scale well
 High speed communication
requirements
 Complex applications and high
IO count
 PLC Platform Independent
WinCC OA

13. WinCC OA
for Oil & Gas
Upstream
Midstream
Downstream

14. Distributed Generator Management
WinCC OA Case Study

15. Motivation for Change
 Current Solution
 Several external solutions stapled
together
 Upgrades and maintenance external
 Regional requirements restrict sales
 Proposed Solution
 Single, cohesive platform, built on a
proven platform
 Maintaining/upgrading can be done
internally, with ownership of source code
 New features and added benefits will
come with new solution

16. Project Requirements
 Support revised generator designs
 At Company HQ: Monitor Faults, Track
Performance, etc.
 Local Control for operator
 Local Data Collection (with backup at HQ)
 Flexible addition of new sites as operation
grows
 Customer ownership for future changes

17. Key Features
1. Distributed Architecture
2. Easily Scalable
3. Auto-generation of New Sites
4. Remote Monitoring/ GIS Viewer
5. Data Collection
6. Custom Tools & Configuration Aides
7. Multi-User, Reusable Development
8. Ultralight Client and Web UI

18. Key Features
1. Distributed Architecture

19. Case Study: Distributed Generators
HQ
ClientClient
Client

20. O&G: Distributed Well Sites
HQ
SiteSite
Site

21. O&G: Pipelines
HQ
Stations

22. Key Features
2. Easily Scalable

23. +
Case Study: Distributed Generators
• Expandable into hundreds of sites
• One to dozens of generators of
varying types
• Types can vary from site to site.
• A site doesn’t have to care about
changes at other locations
• Data from existing older systems
can be virtualized to be viewable
on new WinCC OA system.
• Integrates all operations without
hardware revisions.

24. O&G: Distributed Well Sites
• Single remote site may
contain a variable number of
stations
• Tagged to identify with that
particular site.
+Site1 Site2• Each site can have
unique configurations.
• Additions/modifications
only affect that one site.

25. O&G: Frack Site Trucks/Skids
• Modular, object-oriented
• Not bound to a particular
structure, may be moved and
reassigned as an operation
develops
• Site A does not need n
Skids of type 1, m skids of
type 2, etc.
+
B
X

26. Key Features
3. Auto-generation of new
sites

27. Case Study: Distributed Generators
Remote site configuration handled through a custom tool
1. User selects generator type and IP address
2. System automatically builds out data points, connections,
and graphics representation

28. Case Study: Distributed Generators
3. Remote site programs
configured to seek out HQ
server
4. Connection made
automatically
5. HQ server scans for new
connections and rebuilds its
data points and graphics to
match

29. O&G: Distributed Well Sites
• Server needs no changes/updates as
new well sites brought online
• Configuration manageable by any
interface from the site (direct screen to
box, web UI, mobile UI), may even be
modified from the server, if those tools
put in place

30. O&G: Frack Site Trucks/Skids
• Site actively seeks new trucks
• Server needs no specification of
each new site
• Truck/skid could be scripted to
auto-connect and deploy on
connecting to a new site on
arrival
• Replaces manual config
tool
• Site seeks out HQ
• HQ pulls updates of data points
+

31. Key Features
4. Remote monitoring/
GIS Viewer

32. Case Study: Distributed Generators–
Remote Viewing
• Navigation available and configurable for:
• overview of all sites
• single-site overview
• individual generator
• Layout is dynamic
• Can sort order of appearance

33. Case Study: Distributed Generators–
Remote Viewing
• Custom P&IDs and status summaries developed for
individual generator types and aggregated site data

34. Case Study: Distributed Generators –
GIS Viewer
• Map-bound overview of all active sites
• Filtering of sites displayed by generator statuses,
connectivity, maintenance scheduling

35. O&G: Distributed Well Sites
• Site representations may be filtered/stylized based on statuses,
connection, values of interest, etc.
• View multiple sites in aggregated views
• With proper permissions, connection to control logic even available

36. O&G: Frack Site Trucks/Skids
• Dynamically arrange all trucks/skids connected to a particular site
• Grouping by type, functionality, etc.
• Create combined P&IDs for entire site setup using all
connected systems

37. O&G: Pipelines
• Monitor all stations along
pipeline in relation to each
other
• Locate related statuses
quickly and intuitively
• Easily navigate large numbers
of stations and zoom in on
areas of interest
• Condense thousands of
stations to a filtered, prioritized
list
• Find all faults, alerts, sort
by location, sensor values,
etc.

38. Key Features
5. Data Collection

39. Case Study: Distributed Generators
• Integrated data logging with billing
activities for customer’s leased
generators
• Auto-generation for usage reports
• Analysis of downtime vs. usage, power
production
• Analysis of most common alerts and
maintenance activities
• Reporting ranges configurable
• Useful for long-term evaluation and
maintenance

40. O&G
• Site data may be aggregated by
site, system, or device type into
dedicated tags to share with HQ
server
• On-station data processing to
further reduce data traffic
• Robust local logging, independent
of current connection
• Periodic backup to central server
• High speed data logging available

41. Key Features
6. Custom Tools &
Configuration Aides

42. Case Study: Distributed Generators
• DMC created architecture, but the
customer is given control where
revisions predicted
• New site deployment
• Generator parameter assignment
• Custom tools to allow customer to
make changes without touching the
IDE
• Plans to build extended tools in
future project phases
+

43. O&G: Distributed Well Sites
• Scripted tools mean new site
deployments handled
internally – no wait time or
extra cost to bring in an
integrator for each new site
or hardware change
• Configuration tool could
modify what calculations are
run and what data is
collected/relayed for each site
operation without interrupting
runtime
+
+

44. O&G: Frack Site Trucks/Skids
• Nearly every startup
operation can be
automated
• No need to pull in
integrator for a v2 skid
• Central data analysis
changeable without
modifying truck/skid
code
• Deployment speed
much faster B

45. O&G: Pipelines
• Status reporting,
commands, and data
aggregation
customizable
• E.g. may perform
analysis on-site,
and only pass
relevant
metrics/alerts back
to HQ
• Large-scale, repeating
initializations,
configurations, and
commands may be
turned into single
operations

46. Key Features
7. Multi-User, Reusable
Development

47. Case Study: Distributed Generators
• Development environment highly
conducive to code reuse
• Tools capable of bulk edits and
development, reducing repetitive
tasks and low-value engineering
time
• Create objects, similar to
blueprints, for future
development.

48. O&G
• Separate system
representations and
controls can be
developed in parallel,
increasing rate of
implementation
• Can break work down
across several
engineers
• Object-oriented
model implicitly reuses
similar features of
similar devices

49. Key Features
8. Ultralight Client and
Web UI

50. Case Study: Distributed Generators

51. O&G: Pipelines
• View station status on-site without having to bring over a
full HMI or monitor, and without having to install an HMI
for each station
• Just bring a phone or tablet and transform it into a
station UI for monitoring, configuration, etc.

52. Other Features & Options

53. SIL-3 Certified
• WinCC OA is the only
available OEM SCADA
platform that is SIL-3
certified
• Certified on all versions
that come out for the
next 3 years

54. Video Integration
• Unique to market - DVR-like video capture
• Can tie recorded video to alarm and events
manager
• Can hold 2-3 minutes of video in circular field
and then stop disposing when there is an event.

55. Recap
1. OA is perfect for distributed
architectures
2. Scales easily as your system grows
3. Tools can be configured to auto-
generate new components, make
updates without needing integrator
4. Monitoring, data collecting, long-
term tracking done easily

56. Questions?

57. Unrestricted © Siemens Industry, Inc. 2015 All rights reserved.
James Condon James.Condon@dmcinfo.com
www.dmcinfo.com