John Sullivan from DMC presented on WinCC Open Architecture (OA) and how it can be applied to oil and gas projects. Key features of WinCC OA include its distributed architecture, scalability, ability to auto-generate configurations for new sites, remote monitoring capabilities including GIS viewing, integrated data collection, custom configuration tools, support for multi-user development, and ultralight web and mobile clients. Case studies were presented on how WinCC OA has been used for distributed generator management and how its features translate well to applications in upstream, midstream, and downstream oil and gas.

1. Siemens Industry Oil and Gas Conference
March 30th, 2016

2. John Sullivan
Improving and Scaling SCADA Systems:
Is WinCC OA Right for Me?

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

4. Presenter Info
John Sullivan
Project Director
• Siemens Certified Professional
• Control Systems PE
• B.S. in Mechanical Engineering – Rose Hulman Institute
of Technology
• With DMC since 2009
• Relocated to Denver in August of 2014 with 3 other
engineers.

5. DMC Company Profile
Industries Served:
Automotive
Chemical and Food
Processing
Electronics/Semiconductor
Hydraulics
Laboratory Testing
Machine Tool
Material Handling
Metal Converting
Packaging
Pharmaceutical
Printing & Textiles
Oil & Gas
Established in 1996, offices in Chicago, Boston, Denver,
Houston, New York & customers throughout the world
employees & growing
85+

6. Areas of Expertise

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

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

9. CUSTOM SOFTWARE
& HARDWARE DEVELOPMENT
PC Application
Development
Product
Development
Web Application,
iOS, Android &
App Development
Embedded
Design &
Programming
SDK, API
& Driver
Development
Database Systems

10. MICROSOFT CONSULTING SERVICES
10
10
5
5
INDIVIDUAL
CERTIFICATIONS

11. Manufacturing & Automation Certifications
DMC has the highest number of
S7 certified engineers in the US.

12. WinCC OA Introduction

13. 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

14. Background
 Started in Europe
 5000+ installations
all over the world
 Entered into US market
~ 5 years ago
WinCCOA

15. 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
WinCCOA

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

17. Distributed Generator Management
WinCC OA Case Study

18. 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

19. 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

20. 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

21. Key Features
1. Distributed Architecture

22. Case Study: Distributed Generators
HQ
ClientClient
Client

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

24. O&G: Pipelines
HQ
Stations

25. Key Features
2. Easily Scalable

26. +
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.

27. 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.

28. 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

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

30. 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

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

32. 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

33. 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
+

34. Key Features
4. Remote monitoring/
GIS Viewer

35. 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

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

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

38. 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

39. 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

40. 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.

41. Key Features
5. Data Collection

42. 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

43. 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

44. Key Features
6. Custom Tools &
Configuration Aides

45. 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
+

46. 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
+
+

47. 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

48. 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

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

50. 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.

51. 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

52. Key Features
8. Ultralight Client and
Web UI

53. Case Study: Distributed Generators

54. 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.

55. Other Features & Options

56. Security
• SSL certificate generator
• Optional Kerberos Authentication
• Can’t be accessed through spoofing or IP
indirection

57. 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

58. 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.

59. 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

60. Questions?

61. John Sullivan John.Sullivan@dmcinfo.com
303.927.0191 www.dmcinfo.com