A steel mill plant faces challenges in integrating its disparate building management systems across multiple facilities due to different systems, protocols, and infrastructures. Schneider Electric offers a solution that provides connectivity, reliability, and scalability through a central unifying system. This allows information sharing and advanced control capabilities. Examples of successful integrations at NASA and a large tower complex in Japan are presented to demonstrate the benefits of monitoring and controlling entire campus operations from a single control room.

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