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The Challenges and Solutions to Integrate Multi-Facility/Buildings Disparate Management Systems Across a Steel Mill Plant – Dave Hreha


As presented at AIST 2014: This presentation describes how Multi-Facility SCADA and Historian solutions can be used within Steel Mill Plants as the single interface for monitoring and controlling all …

As presented at AIST 2014: This presentation describes how Multi-Facility SCADA and Historian solutions can be used within Steel Mill Plants as the single interface for monitoring and controlling all Steel Mill Facility Building Management Systems. This solution helps facility operations operate and maintain their buildings from a single environment without having to use multiple Building Management Systems, while maintaining all existing multi-vendor hardware by using software solutions for direct connectivity to the buildings control system, and without the need for hardware gateways. As a result, Steel Mill Plant Facility Operations see increased operating expenses and more maintenance time spent on maintaining, training and operating these disparate management systems.

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  • 1. The Challenges and Solutions to Integrate Multi- Facility/Buildings Disparate Management Systems across a Steel Mill Plant Steel Mill Plants have multiple building management systems in each building, let alone across many buildings across a Steel Mill. Learn about Schneider Electric’s Steel Mill Plant Facilities visualization and control solutions which allow multi-facility buildings to operate in a “single pane of glass” environment to monitor and control all facilities 1 facilities Presenter: Dave Hreha Applications Engineer
  • 2. Agenda CHALLENGES • Multiple BMS / Power / Facility Control Systems across a steel mill plant • Data in multiple systems (Difficulty in Reporting) OFFERINGS & SOLUTION • Solution -- Connectivity, Reliability, Scalability • Solution -- Rich Features ARCHITECTURE Examples 2 ARCHITECTURE Examples • Caterpillar • NASA • Mori Towers
  • 3. A Typical Steel Mill Facility / Building Setup Natural Gas Meters Water Meters Compressed Air Meters Temperature Sensors Pressure Sensors Electric Meters HVAC Equipment SCADA Weather Data BMS Lighting Steam Meters Metering System 3 ●Systems operate in isolation ●Information not shared across platforms ●Asset data is often duplicated Occupancy Sensors Light Sensors Meters Security Lotus Notes Renewable Power Maintenance System
  • 4. Steel Mill Plant: Integration Issues Compounded •Legacy Equipment, Policies, Administration, and Competing approaches • Legacy equipment is easy to integrate compared to multiple buildings & telecommunications infrastructures. • Some are open, others are proprietary and/or obscure. 4 •Differing telecommunications infrastructures • Transaction-based middleware can’t provide consistent performance or reliability •Differing densities of Measurement Instrumentation • Some buildings have a sufficient number of sensors & meters to provide sufficient data for an energy efficiency play. Others have little to nothing at all.
  • 5. The Intelligent Steel Mill Facilities ● Systems share information through a central, unifying system ● An interconnected smart Steel Mill Buildings operations Natural Gas Meters Water Meters HVAC Equipment SCADA Weather Data Renewable Power BMS Lighting Steam Meters 5 enables advanced control and a higher level of automation to save energy and improve productivity Meters Compressed Air Meters Occupancy Sensors Light Sensors Temperature Sensors Humidity Sensors Pressure Sensors Electric MetersSecurity Lotus Notes Maintenance System Metering System
  • 6. SCADA Systems includes more than 150+ communication drivers Multiple Platforms = Multiple Protocols • Open Standards • BACNet • OPC • Modbus • LONWorks • DNP 3.0 • Industry Standards • Johnson Controls • Siemens • Mitsubishi • Satt • Moeller NO Hardware Gateways 6 • DNP 3.0 • IEC 61850 • SNMP • ASCII • C-Bus • Moeller • ABB • Danfoss • Exomatic • Landis & Staeffa • M-Bus • S-Bus • Allen Bradley • SAIA Gateways Required!! Native Software Connectivity
  • 7. Solution offer vision 7 Multiple silo systems Integrated Solution
  • 8. Reliable system architecture 8 •Automatic Client Switchover • Alarm &Trend Synchronization between Servers •Alarm & Event Notifications •99.9% System Uptime •Automatic Failover •Automatic Recovery
  • 9. Scalability •Scalable •Virtually unlimited expansion •Clustered distribution •Installations with over 2 million devices •Installations with over 200 locations • Multi-threaded • Multi-CPU • Multi-Cluster 9 9 •Installations with over 200 locations •Installations with over 100 CALs
  • 10. One central control room ●The ability to monitor all your Campus Operations from a single control location affords you: •Better operational efficiency, •Better maintenance efficiency, 10 •Better maintenance efficiency, •Better energy efficiency, •Less manpower requirements and, •Reduced operating costs.
  • 11. Rich Features - Alarm Management ●Single Alarm Interface for all Campus Systems ● Sequence of Events View ● Alarm History ● Operator Comments 11 ● System Event Tracking
  • 12. Rich Features - Data Analysis (Trending) • One Trend display for: • Power Consumption • Facility Equipment Data • Alarm Conditions • Environmental Data 12 • Capabilities • Overlay similar events • Split screen • Unlimited Tag Visibility • Campus
  • 13. Rich Features – Camera Integration ●View video feed from cameras directly on the Visulization displays ●Keep a greater watch over secured areas and high-value equipment and materials to improve security ●Protect equipment by visual 13 Effective remote monitoring functions via pre-programmed positions of the camera pane ●Protect equipment by visual verification of the system operation in conjunction with the live operating metrics ●Alarm Association for any alarm condition configured for any system, to automatically pop up upon occurance!
  • 14. Rich Features - Time Schedulers Hierarchy defined from equipment name. Children inherit parent’s state. Scheduled mode can be overridden and state changed. Reduce Energy Demand by altering device output during peek times (e.g. Lighting, HVAC) 14 Schedules can be on off, or recurring. Recurrences are fully customizable.
  • 15. Reference #1 (Installed in 1998) NASA’s KCCS System Architecture KCCS Utility KSC IT Business Network Kennedy Complex Control System Power Subsystem Control and Monitoring Architecture Diagram Firewall Secure KSC Industrial Ethernet Backbone-Power (Fiber) SecureKSCIndustrialEthernetBackbone(Fiber) Primary Controller KCCS Standard FIC File Server/ ADSP Trend Server I/O Server 1 I/O Server 2 I/O Server 3 Primary Servers(LCC1P9) File Server/ ADSR Trend Server I/O Server 1 I/O Server 2 I/O Server 3 Redundant Servers(LCC1P9) UPS ATS Generators Analogs Contacts Contacts/Analogs O2 Deficiency Monitors 15 Architecture for Utility System is similar, but with 1 redundant I/O server set and end items would be AHUs, Pumps, Chillers, etc. Utility Network Display Client SGS EMO HQ Secure KSC Industrial Ethernet Backbone(Fiber) Display Client NASA PH OSB5th LOAD LOAD Smart Substation Interface Secure KSC Industrial Ethernet Backbone(Fiber) Display Client SGS Shop K61446 Display Client USA Shop k7569 PowerMeter Srv C5 Substation C5 EPP Wonderware Workstation PowerLink Controllable Breakers (Lighting and Small Motors)
  • 16. Reference #1 - NASA (Installed in 1998) Power System Supervisory & Control Screen 16
  • 17. Reference #1 - NASA (Installed in 1998) UPS System Supervisory & Control Screen 17
  • 18. Reference #1 - NASA (Installed in 1998) Chilled Water System Supervisory & Control Screen 18
  • 19. Reference #1 - NASA (Installed in 1998) Air Handler System Supervisory & Control Screen 19
  • 20. Reference #1 - NASA (Installed in 1998) Utility Shop Overview -Supervisory & Control Screen 20
  • 21. Reference #2 -Mori Towers Solution Overview (Installed 2008) Facility-wide Monitoring, Control & Reporting • HVAC • Lighting • Energy Management (WAGES) • Reporting • Fire and Security 21 21 • Fire and Security • Equipment / Activity scheduling Requires strong communication capabilities to the Building Automation sub-systems, and an integrated Scheduler
  • 22. Reference #2 -Mori Towers (Installed 2008) Visualization - Overview Easily identify poor tenant behaviour 22 22
  • 23. Reference #2 -Mori Towers (Installed 2008) Visualization – Floor Plan Status ‘hot-spots’ to display details 23 23
  • 24. Reference #2 -Mori Towers (Installed 2008) Control Status ‘hot-spots’ to access equipment details and controls Manage HVAC parameters 24 24
  • 25. Conclusion………… • Facility Managers need solutions that can assist them to keep operational costs low, Energy Efficiency high, and their facility in top working order, such as • Campus Systems that can work together to extend beyond their individual capabilities and enable a truly intelligent campus • Scalable solutions for Campus Monitoring & Control that can scale to large scale commercial enterprises. 25 25
  • 26. Questions? 2626