CNG IN A BOX: Cloud Based Enterprise Historian w\dash Boarding Solution for CNG Fueling Stations

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1 CNG IN A BOX: Cloud Based Enterprise Historian w\dash Boarding Solution for CNG Fueling Stations Project: CNG in a BOX: Cloud Based Enterprise Historian w\dash boarding for CNG Fueling Stations. 1. INTRODUCTION A prototype for hosted cloud-based automation, monitoring & historian application that provides CNG Fueling/Marketing companies with the ability to monitor their assets, analyze production, and assist their customers (from their current positions) to locate and get maximum information for nearby CNG stations. Since this application is a web-based service, the only thing users need to start monitoring their field devices is an internet connection, a browser and a password. The prototype also includes a Mobile application that will run a on any smartphone or tablet device. CNG in a BOX application leverages the power, scalability and redundancy of a true cloud platform. It runs on Microsoft s Platform as a Service (PaaS) called Windows Azure. It is offered as Software as a Service (SaaS) providing customers with a comprehensive solution at an economical price. Customer will only pay for active devices being monitored and only pay for what they are using. 2. SCOPE OF SERVICES PLATFORM as a Service (PaaS) Cloud Based Infrastructure Storage Data transfer Storage Transaction Historian Solution as a Service (SaaS) HMI/SCADA Process Historian Dashboards/PIMS Portal Mobile Service (application) Mobile Application/Portal Development Engineering Services SCADA / HMI and Integration with simulated RTUs Configuring Advanced Process Historian and Archiving RT-PIMS Portal / Dashboard and Ontology / Contextualization Web port for Cloud Access Types of USERs Executive Users/Super Users Mobile Users Page 1 of 14

2 3. Typical Architecture 4. Main Difference with Traditional SCADA Essential Characteristics On-demand Self-service Broad Network Access Resource Pooling Rapid Elasticity Measured Service Main Benefits Economic Benefits Better Agility Greater Accessibility Improved Reliability Superior Security Page 2 of 14

3 Deployment Models Private Cloud Public Cloud Hybrid Cloud Service Models Infrastructure as a Service (IaaS) Platform as a Service (PaaS) Software as a Service (SaaS) 5. SOLUTION DETAILS CNG in a box is a Microsoft Azure Platform (Windows 2008 Server Virtual Machine) that hosts IntelliMAX as Plant Historian w/ Data Acquisition, Alarms & Events Logging, Trends & Dashboards/Reporting capabilities. Executive users/ super users have access to the Reporting/Visualization Portal from anywhere using Internet Explorer. Figure: CNG IN THE BOX-Architecture Page 3 of 14

4 5.1 Device Layer Spectrum WebPort is a remote access gateway that allows interacting with field devices from virtually anywhere. WebPort Connects is cloud-based service (will be installed in the Azure cloud Platform) which provides secure virtual private network (VPN) access to Web Ports and automation devices (RTUs, PLCs, PCs) deployed at any given CNG Station. The following diagram illustrates Spectrum Web port Connect (VPN cloud service). AZURE Platfrom MICROSOFT 2008 SERVER VM RTU PC VPN SERVICE (VIRTUAL LAN) W E B P O R T C O N N E C T M O D B U S E T H E R N E T DASH BOARD DATA LOGGING ` Figure: Spectrum Web Port Connect (VPN Service) Illustration Web Port Connects uses the secure socket layer (SSL) to establish a connection to the outside world resulting in reliable highly successful deployment. The following architecture diagram shows Spectrum WebPort working. Figure: Spectrum WebPort (Gateway) Working Architecture Page 4 of 14

5 1. Pre-Requisites: Internet connection (for WAN connectivity) (Web Port by Intech, phone line) SIM card from cellular provider and cell antenna (for cellular connectivity) 12 to 24 volt DC power supply 2. For Internet Connection (Microsoft Azure Platform: Historian Virtual Machine) via Ethernet: Connect Ethernet cable from Spectrum Web port WAN port to the internet service 3. Connect RTU/PLC/PC to LAN Port: Connect Ethernet cable from LAN Port to the PLC/RTU/PC (or any other device at the given unit i.e. CNG Station). 4. The Web Port s LAN IP & WAN IP address appears on the scrolling display Figure: Spectrum WebPort Illustration 5. Device Connectivity: The WebPort speaks several communication protocols as shown in the diagram below. Figure: Spectrum WebPort on the Azure Platform: Devices Connectivity Page 5 of 14

6 Figure: Devices Connections/Subscriptions with IntelliMAX Plant Historian on Azure Platform 5.2 Information Modeling Class / Template Definition for CNG Station A modular approach for adding CNG Stations (Units) to the application shall be followed. IntelliMAX allows defining templates (classes) for any real world object modeling. We shall be creating a CNG Station template. Each template has its data items (tags), Template Views (One or more graphical representations), Graphics (e.g. Compressor, Dispenser, Storage, and Controller etc.), Trends, and Alarms Viewers. The following diagram illustrates the definition of CNG Station template. Each CNG station (unit) will be an instance for the CNG Station template. The base information model for CNG Station is defined as: 1. A Control Brick (main control panel and flow meter plus dispenser) 2. A Storage Brick (customer can add more as required by application and local demand for gas) 3. A Compressor Brick (customer can add more as required by application) Following data items are defined for each of the bricks Compressor Brick 1 DI, 1 DO, 2 AI Control Brick 5 DI, 1 DO, 4 AI and 8 calculated values Storage Brick 1 DI, 2 AI and 1 DO. In our solution the information modeling (asset/equipment) is based on ISA-95 standards. Each CNG station is accessed using the following hierarchy (Project ISA-95 Model CNG Enterprises). Page 6 of 14

7 Figure: Object Oriented Design: For CNG Station Class Definition (Data Items) Figure: Object Oriented Design: For CNG Station Class Definition (Views and Graphics) Page 7 of 14

8 5.3 Objects Instantiations Object / Unit Definition for CNG Station Instantiating (or adding) a new CNG unit is very quick and easy. The following diagram illustrated adding a new unit to the application. On clicking the New Unit menu item. A user interface to enter the following information is opened: Name of the Unit: Description: Location: Device: This is the RTU / PLC / PC name that is the data source for this New Unit. If any extension to the CNG station/unit is required it should be done at the template/class level. The changes/updates will be propagated to the instantiated objects/units. Using Right click menu on any instantiated unit user can open its tags list, trends, Alarms Views etc. Figure: Information Modeling using IntelliMAX Objects (Contextualized Tags) Each unit consists of Compressor Brick, Control Brick, Receiving and Storage Brick. Adding more bricks to the units or enhancement to any of the existing bricks shall be done at CNG Station template/class level and changes will be propagated (automatically) to the existing units/objects. The new unit/object will be encapsulating all the updates. Page 8 of 14

9 Figure: Information Modeling using IntelliMAX Objects Control Brick 5.4 Process Historian and Alarms & Events Logger: IntelliMAX Data Acquisition & Logging has been tested with 100,000+ active tags subscriptions. Out of which 3000 subscriptions were continuously updated / second. 5.5 Reports & Dashboards We shall be using Report MAX for reporting & dashboards. Users can share dashboards with their whole company and with customers and partners in minutes. Excel Reporter will connect to IntelliMAX Data Historian using OPC H D A. IntelliMAX historian stores time series data for 1 to N CNG units. E.g. the dashboard in the following diagram focuses on production surveillance. This includes an overview of the FUEL dispensed and a closer look at performance (target vs. actual) by month and by individual unit. Most importantly, we can customize the view using the filter panel at the top, giving you greater control over the information the customer wants to see. Page 9 of 14

10 Figure: Production surveillance - Dashboard Following KPIs will be published in the dashboards. The types of Reports and their format can be customized as per agreement with the customer. Following base KPIs shall be available. New KPIs can also be added. Fuel Flow (amount dispensed) # of Transactions Storage Vessel Refill Time Fuel Dispensed per day, Total Sales, Dispensing Time (avg Vehicle fill time) Page 10 of 14

11 5.6 CNG IN THE BOX MOBILE APPLICATION Mobile Application for Concurrent Users: Prototype Stand Alone Application, downloadable and installable on Android phones The application should be able to present following KPIs (in tabular form) o Current Position & Nearby CNG stations location from current position o Type of station o Prices, pressure and ratings Figure: CNG in the BOX: Mobile Application (Prototype) Mobile Application for Concurrent Users: Final Version Stand Alone Application, downloadable and installable on Android & iphone devices. Integrated with Google maps (offline & Online) Map routes and see nearby stations using Google maps (integration) The application should be able to present o Fueling Capacity o Amenities and Interface to check the amenities o o Interface to book time in Fueling Report per Day/Week/Month: # of transactions, Amount of Fuel Dispensed, Stored, Total Sales etc. Page 11 of 14

12 6. BILL OF SERVICES 6.1 Prototype Item ITEMS Vendor Unit QTY A Platform as a Service (Microsoft Azure) 1 Compute Hours: Virtual Machine (A2) : Virtual Cores = 2, RAM = 3.5 GB 2 Storage (GB/Month) 3 Data Transfer Out (GB)-Zone 1 4 Storage Transactions B Historian as a Service (IntelliMAX) 1 Data MAX Historian (100 Tags) Design Time Interface Concurrent Runtime Interfaces Report MAX License / Tableau License C Mobile Application 1 Stand Alone Application, downloadable and installable on Android phones. The application should be able to present the following KPIs (in tabular form) in the prototype: Current Position & Nearby CNG stations location from current position Type of station Prices, pressure and ratings D Engineering Services 1 Establishing Microsoft Azure Platform with required pre-requisites Installation of Historian & Visualization software Integration with Spectrum Web Port & RTUs Configuring Process Historian and Archiving Designing Real Time Portal / Dashboard and Ontology (Reports) Testing (to load and test the complete package) FAT / System Staging Training services for the above software items 1 day application training Microsoft SENSYS Pay-As- You-Go Billable on Number of Hours Consumed LS 01 INTECH Days 14 INTECH Days 14 Page 12 of 14

13 7. PRICE SUMMARY: CNG in a BOX (Cloud) 7.1 Prototype Project SN System Price Reference 1 *Platform as a Service A2 (2 cores and 3.5 GB RAM) USD 6,194.00/yr 2 Historian/w Reporting & Dashboards as a Service (100 tags) Only Reporting Billable. USD 1, **Engineering Services (Including Mobile application development) *Based on 8928 hours per year (maximum usage) **Engineering day = USD 1200, Man days = 28 USD 33, Per Sellable CNG Station for one SN System Price Reference 1 *Platform as a Service A3 (4 cores & 7 GB RAM) USD 1, /yr 2 Historian/w Reporting & Dashboards as a Service (100 tags) USD 3, Engineering Services (Including Mobile application enhancement and Spectrum Web Port Provision, installation & Configurations). *Based on 8928 hours per year (maximum usage) **Engineering day = USD 1200 USD Per Sellable CNG Station purchased in lots of 20 units SN System Price Reference 1 *Platform as a Service A3 (4 cores & 7 GB RAM) USD 1, /yr/unit 2 Historian/w Reporting & Dashboards as a Service USD 1,100.00/unit 3 Engineering Services (Including Mobile application enhancement and Spectrum Web Port Provision, installation & Configurations). *Based on 8928 hours per year (maximum usage) **Engineering day = USD 1200 USD 2,400.00/unit Page 13 of 14

14 8. PRICE SUMMARY: CNG in a BOX (with Historian: Visualization, Reporting, Dashboard on Customer Servers) 8.1 Per 01 Sellable CNG Station SN System Price Reference 1 2 Historian/w Reporting, Visualization & Dashboards on customer servers (for 100 tags) *Engineering Services (Including Mobile application enhancement and Spectrum Web Port Provision, installation & Configurations). *Engineering day = USD 1200 USD 3, USD 3, Per 10 Sellable CNG Stations SN System Price Reference 1 2 Historian/w Reporting, Visualization & Dashboards on customer servers (for 1,000 tags) [ 20% Discount] *Engineering Services (Including Mobile application enhancement and Spectrum Web Port Provision, installation & Configurations). *Engineering day = USD 1200 USD 4, USD 2,400.00/unit 8.3 Per 20 Sellable CNG Stations SN System Price Reference 1 2 Historian/w Reporting, Visualization & Dashboards on customer servers (for 2,000 tags) [ 25% Discount] *Engineering Services (Including Mobile application enhancement and Spectrum Web Port Provision, installation & Configurations). *Engineering day = USD 1200 USD 6, USD 2,400.00/unit 8.4 Per 100 Sellable CNG Stations SN System Price Reference 1 2 Historian/w Reporting, Visualization & Dashboards on customer servers (for 10,000 tags) [ 30% Discount] *Engineering Services (Including Mobile application enhancement and Spectrum Web Port Provision, installation & Configurations). *Engineering day = USD 1200 USD 7, USD 2,400.00/unit Page 14 of 14

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