Foxboro Control Systems Strategic Overview and Direction

Transcription

1 Foxboro Control Systems Strategic Overview and Direction 2013 Invensys. All Rights Reserved. The names, logos, and taglines identifying the products and services of Invensys are proprietary marks of Invensys or its subsidiaries. All third party trademarks and service marks are the proprietary marks of their respective owners.

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3 Foxboro Evo Introduction and Overview

4 Our Foxboro Paradox Continuously Current. Proven I/A Series technology designed to keep you future proofed 1980s 1st distributed software 1st open industrial system 1st Ethernet control bus 1st object software 1st standard UNIX 1990s 2 msec logic in I/O Redundant fieldbus 1st embedded digital fieldbus 1st Windows NT-based control Adaptive feed forward control 1st expert controller tuning 2000s Legacy DCS plug-in migration All digital instrument bus Self-healing 1gb Mesh Network Anybus fieldbus integration 1st on Windows XP & Solaris 8 1st Redundant, secure, high speed, Ethernet remote I/O Today FDSI Superior integration to third parties 1st InFusion Enterprise Control Intrinsically safe I/O Cyber Security Enhancements 100 Series Upgrade Program Next gen controller Wireless Network Next gen HMI & Eng tools Universal I/O Dynamic SAMA CP280 Situation Awareness Graphics Field Device Manager

5 Perception: I/A Series system is stuck in the 80s.

6 Reality: Field Device manager for HART Workflow, OTS, Advanced Apps Situational Awareness library Virtualization ArchestrA Graphics conversion Foxboro Control Software Visualization & Configuration Cyber Security hardening Dynamic SAMA Object Manager CNI Control & Safety Integration FCP280 Simulated- CP Wireless Mesh/HART Intelligent Marshaling 100 Series Migration We have a modern system

7 How do I Identify and eliminate risks? Maximize plant availability? Prevent security risks? Get the right information? Diagnose variety of technologies? Predict problems and reduce risk? Reduce overall costs? Maximize production value? Ensure safety, security and compliance? Identify and resolve problems fast? Deal with evolving technology? Many different systems to deal with Design systems for the future Deal with changing requirements Run plant at peak performance? Quickly handle abnormal situations? Ensure 100% safe operation?

8 Top Benefits to Customer Safe, available, secure No single point of failure Increased Cyber Security Unified Safety interface Reduced unplanned downtime through: Contextualized alerts & Guided workflow Integrated Field Device Management Faster commissioning and repair Lowest total cost of ownership Real-time dashboards Enterprise modeling & monitoring Enhanced security & safety Reduce workload & reduce risk: Doubled FCP processing speed in smaller footprint Remote engineering configuration & testing Reduced Mean time to diagnose Improved operator response & productivity Reduce human fatigue and operator error Synchronized role-based responses to events Managed workflows and audit trails

9 Process Automation System Overview Control room side Engineering Suite Operations Suite Maintenance Suite Applications Integrated, yet separate control & Safety Unified Communication Module Controllers CP280 High Density I/O Process-connected side

10 Agile development process Benefits - Smaller Development sprints to verify functionality - More release increments - Greater flexibility for early access - Work on feature back log - SAMA is a great example

11 Committed Deliverables FCP280 SAMA complete Control strategy layout & print On-sheet Logic Dec. 13 New Historian Redundant 500k tags FoxView support Situation Awareness Graphics Integrated Safety Maintenance Response Center High Density IO Operate Anywhere Engineer Anywhere Within 6 months Control Network Interface (CNI) New Gateway Processor Within 12 months Triconex Software Integration (TSAA DI Object) Historian 2,000,000 tags Driven by Agile Development process

12 Functions of People Who Use Our Systems Safety Engineer System Engineers Project Engineers Maintenance Technicians Operations Manager Operate

13 Operate Function As a Control Room Operator my job is to: Run the plant at peak performance Ensure continuity of production Manage changing production schedule Identify and resolve production problems Ensure safe operation Challenges I face: Human error - A factor in more than 40% of abnormal situations in the process industries Abnormal situations - Cost the process industries an estimated $20 billion per year Reduced human reliability - Resulting from known barriers

14 Operators Challenges 1970 s 1980 s 1990 s Present Trend Operator Impact Plants are larger, more complex Increased monitoring load Lack of understanding Increased instrumentation More data to manage Lost in the details Increased automation Operators become disengaged Role is reduced to dealing with upsets Centralized operations Loss of direct awareness

15 Demo Operations Situation Awareness Graphics 1. SAL Demo

16 Engineering Function As an on site Systems Engineer my job is to: Identify and resolve production problems Diagnose and remediate faulty equipment Continually improve production Expand systems Deal with process design modifications Ensure safe operation Challenges I face: Many different systems to deal with Time is of the essence Computer technology evolves rapidly Have to keep my system up to date so it can be serviced in a breakdown situation

17 Systems Engineers Challenges Sequential Flow charts Ladder Logic Function block diagram Structured Text None of these intuitively expresses what is actually going on

18 Demo Engineering 2. Config tools

19 Engineering Function As a Project Engineer my job is to: Construct new and upgrade old systems - suit production and safety requirements Drive first production Deliver a system that the owners may use, maintain and expand for the lifetime of the plant Ensure the system solves diverse problemsminimize technology overhead Challenges I face: Risk to schedule Ever-changing requirements Architecture that meets physical requirements Compliance to appropriate standards

20 Meeting the Need I/A System System 1 CNI 1 CNI 1 Intelligent Marshaling: Flexible IO assignments CP280: Powerful control processor Requiring fewer of them Non-I/A Network CNI 2 Virtualization and Thin Client System 2 I/A System Control Network Interface: To manage large or geographically dispersed system CNI 2

21 3-Point Strategy Decoupling key components DECOUPLE s/w applications from hardware Virtualization DECOUPLE IO specific deliverables Intelligent Marshalling Intelligent Project Execution Intelligent Engineering DECOUPLE Engineering from geography and location

22 Typical Execution Schedule 3mth 3mth 3mth 3mth Life time Order Placement System Design Functional design Workstation procurement Cabinet design build Test design build Workstation Ship to Site procurement System configuration System configuration Integrated FAT Continuous Revision Cycles Install Ship to on Site Site Integrated Install on FAT Site Install on Site Install Site on Site Site Acceptance Acceptance Lifetime Update cycles and expansions Acquire Hardware later Improved lifecycle Ship generic IO to site Schedule gain Decouple Engineering Schedule gain Continuous revisions Change agile

23 Maintenance Function As a Maintenance Technician my job is to: Diagnose and remediate faults instruments, valves, system components Tune control loops Perform routine maintenance Anticipate faults due to wear and tear Ensuring asset integrity (reliability & availability) Challenges I face: Many different types of equipment Modern instruments - so sophisticated it takes time to identify root causes Many competing standards Having the right tools for the job Extracting the value of intelligent devices Time is of the essence

24 Maintenance Technicians Challenges + Foundation Fieldbus HART DeviceNet Profibus FDT Device Descriptors Files GSD Files Enhanced DD Files DTM Device Type Manager Too many tools and technologies!

25 Demo Maintenance 3. Maintenance Alert Centre

26 Protect Function As a Safety Engineer my job is to: Identify hazards and risks Determine the likelihood, frequency, consequence and severity Quantify and qualify the Risks Implement Safe guards to manage the risk to an acceptable level Document the risks and safety requirements Challenges I face: Compliance with appropriate standards Ensure safeguards are operating as designed Identify, plan and manage the operational risks Avoid exposure to production outages, equipment damage, environmental incidents, injury to personnel

27 Meeting the need Unified integration of DCS engineering and operational environments. Solution Triconex configuration integrated with the Control system Single data entry, common configuration environment Fully integrated real time, SOE and alarm data Tricon Trident Tri-GP Triconex as a control station on the Control Network Unified system management UCM Benefits Lower Total Cost of Ownership Reduced physical space Faster installation & commissioning Maintain Separation Invensys Proprietary & Confidential

28 Unified Control & Safety Operator Workstations Real Time Data Historian Alarms / SOE Engineering / Maintenance Workstation Engineering Galaxy Repository Control Network Process Controllers Safety Controllers Dedicated Safety Peer to Peer

29 Maintain Separation Safety Network (Peer to Peer) Control Network Safety Triconex Communications Module (TCM) Control Unified Communication Module (UCM)

30 Integrated USER EXPEREINCE Engineering / Maintenance Workstation System Monitor Pane TCX001 System Management Information Control Network Pane Safety System Information Pane Station Information Pane

31 Protect Function As a System Administrator my job is to: Ensure safe operation Ensure availability of the system Plan capacity and utilization of the system Install system updates Root cause analysis Protect the system from unauthorized users Back up and restore managements System Inventory management Business continuity Challenges I face: Changing compliance and regulations Manage audit trails and documentation Monitor firewalls Change management Version management Information security

32 Meeting the need Network access (firewalls) Station Assessment Tool Physical access protection Workstation security OS-based ArchestrA Security Off-Mesh Active Directory Whitelisting Cyber Security Consulting Critical Infrastructure & Security Practice (CISP) User accounts and passwords Active directory group policy WurldTech Certification USB blocking BIOS settings Local group policy Remove unused software Disable unused services anti-malware least privilege Domain authentication for ArchestrA and InTouch logins virus scan

33 Manage Function As an Operations Manager my job is to: Manage safety of the operation Ensure the plant runs to maximum productivity and profitability Manage all staff to execute on company strategy Challenges I face: Changing Market demand Manage variable costs Report to executives and board Personal accountability / liability

34 Meeting the need InFusion Enterprise Historian Real time Finance Historian clients Enterprise control Unified system System of Systems Industrial Service oriented Architecture Business continuity planning Life Cycle Management Reduced Unplanned Downtime Business Value Consulting Security Real time cost control Corporate energy management Enhanced Security and safety Workflow Business Process Modeling Business Analysis Dynamic Performance Management

35 Meeting the need with Enterprise Control Performance Management EMI Quality Asset Performance KPIs Operations Mgmt MES EAM Mobile Workforce Industry Applications Energy Mgmt Planning ROMeo Common industrial service oriented architecture creates opportunity to expand from process control to enterprise control within one system

36 What stakeholders are saying...

37 Getting to the new system I/A Series I/A Series Foxboro Evo IFDC, FDM FDM FDM Foxboro Evo Maintenance Suite Response Center AIM*AT AIM*AT historian historian ICC, IACC, FCSct ICC, IACC, FCSct Engineering Suite Engineering Suite DM, FoxView DM, FoxView FoxView Intouch NodeBus, MESH NodeBus, MESH Control Network Control Network Unified Safety Unified Safety CP30 CP270 CP30 CP270 FCP280 FCP280 FBM100 FBM200 FBM200 FBM200+HD

38 Top Benefits to Users Safe, Available, Secure No single point of failure Increased Cyber Security Unified Safety interface Reduced unplanned downtime through: Contextualized alerts & Guided workflow Integrated Field Device Management Faster commissioning and repair Lowest total cost of ownership Real-time dashboards Enterprise modeling & monitoring Enhanced security & safety Reduce workload & reduce risk: Doubled FCP processing speed in smaller footprint Remote engineering configuration & testing Reduced Mean time to diagnose Improved operator response & productivity Reduce human fatigue and operator error Synchronized role-based responses to events Managed workflows and audit trails

39 Automation Vision

40 Vision Where there is no vision, the people perish - Proverbs 29:18

41 Vision If I have seen further it is by standing on the shoulders of giants Sir Isaac Newton

42 Today - How we Work Environment: Complexity, Push to Extend Old System Lifespan, MoC, Loss of Experience, and Diagnostic challenges Engineer Consequences: Problems Solved Slowly or Deferred, Sub-optimal Solutions, Lowered Production Value, Lessened Safety Environment: Large and growing scope, mostly alarm driven, poor if any automated procedural support, many uncoordinated sources of data Operate Consequences: Reactive Response, Inconsistent Performance, Lower Profits, Lessened Safety Environment: Extend Equipment Life, Limited Resources, Limited Diagnostic Information, Loss of Experience, Lack of Maintenance Centered Automation Maintain Consequences: Problems Solved Slowly or Deferred, Sub-optimal Solutions, Lowered Production Value, Lessened Safety

43 Today - How we Work Environment: Unclear view of Business Strategy, Operational Strategy, and Execution of same, People Unclear of their Personal Impact on Business Manage Consequences: Lower revenues, profits, scale, market share; Employee Dissatisfaction; Risk to License to Operate Environment: Unclear view of Cyber-Security and Plant Safety State, Lack of Comprehensive Understanding of Cyber-Security and Plant Safety Protect Consequences: Latent and/or Unaddressed Threats Leading to Lost Production and Damage / Harm

44 Today Market Drivers Interface expectation based on Gaming Convergence of Process and Business Automation Clients Rely Increasingly upon Supplier Expertise Plant Life Extensions Increasing need to Improve Human Reliability Increased demand for Mobility Increased Government Regulation and new/updated Standards Increased capability of systems to self-diagnose Less mechanical aptitude and greater software insight Smaller internal staff

45 Today - Technology Drivers Designed in Cyber Security (Security Development Lifecycle) Virtualization & Cloud Computing Shift to Universal I/O Module vs. Dedicated I/O Module Modular (Skid-Mounted) Control Systems Single view into all in-plant systems & equipment (field devices, process, safety, electrical, etc.) More Intelligent Field Devices Increasing Reliance on Wireless Field Device Networks

46 Control System of the Future Business Center Information Anywhere Decision Support Applications Engineering Anywhere Network is the Controller Process-connected side Unified Control & Safety Ultra-small I/O Maintain Anywhere

47 Future How We Will Work Engineer Prediction Driven Actions, Consistent Performance, Higher Profits, Heightened Safety Operate More problems solved in less time; Better Solutions, Higher Production Value, Heightened Safety Maintain Prediction Driven Actions, Consistent Performance, Higher Profits, Heightened Safety

48 Future How We Will Work Manage Higher revenues, profits, scale, market share; Increased Employee Satisfaction; Continuous Operation Protect Threats Identified and Addressed Preventing Lost Production and Damage / Harm to Co-Workers, the Environment, and the Community

49 Control Vision Help our Client s Transform Their Business From Process Efficiency Centered Concentration on process control and safety To Business Optimization Centered Concentration on Business Performance within the bounds of safe operation

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