3. What Is Isolated
Integration?
Isolated Integration is a term that has been
applied to the basic idea and base-line
operational requirements of the multilayer
fiber network currently installed and in use by
the Bethlehem Steel Corporation, Sparrows
Point Division’s Slab Group.
Several Basic Operational
Requirements Were:
4. Base Operational Requirements
Capable of handling multiple data types
Level 2 Operating Data
Level 0 – 1 Machine Control Data
General Office Communications
Production and Training Video
5. Base Operational Requirements
Keep data integrity and security by
isolating the various types
GSE Control Levels A and B needed complete
separation
BOF Allen-Bradley PLC Cimplicity HMI control
system isolated
General Office Data (Non-Production Critical)
Production and Training Video (Least Critical)
6. Base Operational Requirements
Flexibility to allow for expansion and
network wide connectivity
Approximately 90% of Installed Machine base is
covered by the phase 1 network cabling
Personnel moves require connectivity to
previously used data in spite of location
Daily request for additional network connections
New, previously unheard of data availability
7. Base Operational Requirements
No dead ends or network limitations
Did not want to run more back bone fiber or
upgrade network equipment hardware
Ability to add new data types without band
width or architecture concerns
Ability to add new operation areas by merely
running copper or fiber to them
8. Base Operational Requirements
Capable of handling multiple data types
Keep data integrity and security by
isolating the various types
Flexibility to allow for expansion and
network wide connectivity
No dead ends or network limitations
Network Architectural Requirements:
9. Network Architectural
Requirements
Use existing Interconnect Cabinets
IC601/IC602 with upgraded Cisco Catalyst
Routers established during initial backbone
installation
48 Strand Multimode fiber – installed,
terminated and tested to comply with Lucent
Technologies Standards. Lower strand count
to non production critical single ended drops
Dual Homed Signal sourcing to give
connection redundancy
10. Network Architectural
Requirements (cont.)
Minimum CAT5+ copper terminations,
capable of transferring data at 100
megabits and above
Primary End User Connection to be
copper with minimal local fiber runs
Single Ended (Non Redundant) Fiber
drops for non-production critical end
users
13. Multi-Layered Cake
Depending upon the
coverage area and
connection requirements
of the individual Switch
Points (SP’s), various
Cisco 2924 Catalyst
Switch combinations can
be placed in the cabinets.
In this diagram each
colored slice represents
a separate Cisco 2924
switch
14. Economical and Flexible
These combinations
have allowed the Slab
Group to implement a
robust, flexible but
economical solution to
empower local
operations and support
personnel with real
time process data.
15. Leading Edge Technology
Building on this foundation of proven Cisco router
and switch technology and through the use of their
VLAN capabilities, we were further able to limit
expenditures in low machine population areas by
subdividing the switches to support a multitude of
secure, isolated networks
17. Flexible Local Empowerment
A typical SP Cabinet, this
one from the installed base
in the Caster, may look
similar to this. Multiple
layers of Cisco equipment
with one of the 2924’s
subdivided into the General
Office VLAN and the Video
VLAN due to the
requirements of the area
and end users
19. Population Growth in 3
Years
8+ Mid-Large
System
150+
Desktop/Laptop
PC’s
25+ GE
/AB PLC
Racks
Video
Video
Video
14 Networked
Process Video
Cameras
5 Operator
Entry Displays
10 - 15
Network
Printers
PLUS…
20. Population Growth in 3
Years Cont.
4 Separate Microsoft SQL Servers
3 Unique Web Servers
Complete DCS Level 1 Caster Control System
BOF Level 0-1 HMI Based Ethernet Control System
4 Wireless Ethernet access points with connections to BOF
Charge Cranes for line-up information
Addition of Vessel Lasers to update Pulpit Operators of Lance
bias’ and lining conditions via Wireless Ethernet
4 Remote Magnetic Tag Readers to monitor Scrap Haulers
1 Oracle Based Data Warehouse
21. Isolated Integration
On a side note – 2 Stories of the
usefulness of the network and it’s
capabilities.
i
2
BOF HMI Ethernet Control
Remote DB Repair and HMI Reboot
22. What Is Isolated
Integration?
Isolated Integration is a term that has been applied
to the basic idea and base-line operational
requirements of the multilayer fiber network
currently installed and in use by the Bethlehem
Steel Corporation, Sparrows Point Division’s Slab
Group.
For the Slab Group, This is the
way we keep our i on the
FUTURE
i
2
23. Isolated Integration
This Network Design could not have
been possible without a true team effort
between:
i
2
Local and Corporate EDS personnel
BSC Corporate IT Personnel
BSC SP Slab Group and IT Members
Be it control office or video data main concerns were data types related to industrial control over ethernet
On top of this backbone web we then added a setup that can be easily compared to a multi-layered cake
This in itself allows for extreme flexibility. But the Cisco equipment provided something else, VLANS
Here we have multiple 2924 configured to fit the needs of the machine type population and user base. The upper right typifies a primarily level 1 control switch integrated with both SCADA and general office. Each network secured and isolated from the other. Below that is a General office switch with 1 to 4 ports configured to support the Video network, again isolated. Finally a pri\mary SCADA configuration with a low population of level 0-1 control.
What drives the layout of the network cabinets again is the equipment and end user requirements. In the Caster the GSE Control system redundancy fit perfectly into the network design and hardware capabilities. GSE A and B are nearly always found together and completely isolated from all network layers. The ability to get to those layers can be added to a port or ports or other switch at other locations to allow access to that data.
