The Challenges and Solutions to Integrate Multi-Facility/Buildings Disparate Management Systems Across a Steel Mill Plant – Dave Hreha
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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 c ontrol all facilities
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facilities
Presenter: Dave HrehaApplications Engineer
AgendaCHALLENGES• 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
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ARCHITECTURE Examples • Caterpillar• NASA• Mori Towers
A Typical Steel Mill Facility / Building Setup
NaturalGas Meters
WaterMeters
Compressed
Air Meters
TemperatureSensors
PressureSensors
ElectricMeters
HVACEquipment
SCADA
WeatherData
BMS
Lighting
SteamMeters
MeteringSystem
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●Systems operate in isolation● Information not shared
across platforms●Asset data is often duplicated
OccupancySensors
LightSensors
Meters
Security
LotusNotes
RenewablePower
MaintenanceSystem
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.
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• 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.
The Intelligent Steel Mill Facilities● Systems share
information through a central, unifying system
● An interconnected smart Steel Mill Buildings operations
NaturalGas Meters
WaterMeters
HVACEquipment
SCADAWeather
DataRenewable
Power
BMS
Lighting
SteamMeters
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enables advanced control and a higher level of automation to save energy and improve productivity
Meters
Compressed
Air Meters
OccupancySensors
LightSensors
TemperatureSensors
HumiditySensors
PressureSensors
ElectricMetersSecurity
LotusNotes Maintenance
System
MeteringSystem
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
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• 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
Solution offer vision
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Multiple silo systems
Integrated Solution
Reliable system architecture
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•Automatic Client Switchover• Alarm &Trend Synchronization
between Servers
•Alarm & Event Notifications
•99.9% System Uptime•Automatic Failover•Automatic Recovery
Scalability
•Scalable•Virtually unlimited expansion•Clustered distribution• Installations with over 2 million devices• Installations with over 200 locations
• Multi-threaded• Multi-CPU• Multi-Cluster
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• Installations with over 200 locations• Installations with over 100 CALs
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,
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•Better maintenance efficiency, •Better energy efficiency,•Less manpower requirements and, •Reduced operating costs.
Rich Features - Alarm Management
●Single Alarm Interface for all Campus Systems
●Sequence of Events View●Alarm History●Operator Comments
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●System Event Tracking
Rich Features - Data Analysis (Trending)
• One Trend display for: • Power Consumption• Facility Equipment Data• Alarm Conditions • Environmental Data
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• Capabilities• Overlay similar events• Split screen• Unlimited Tag Visibility• Campus
Rich Features – Camera Integration
●View video feed from cameras directly on the Visulizationdisplays●Keep a greater watch over secured areas and high-value
equipment and materials to improve security
●Protect equipment by visual
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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!
Rich Features - Time SchedulersHierarchy 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)
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Schedules can be on off, or recurring.Recurrences are fully customizable.
Reference #1 (Installed in 1998)
NASA’s KCCS System Architecture
KCCS Utility
KSC IT Business Network
Kennedy Complex Control SystemPower Subsystem Control and Monitoring Architecture Diagram
Firewall
Secure KSCIndustrial EthernetBackbone-Power
(Fiber)
Sec
ure
KS
CIn
dust
rialE
ther
netB
ackb
one
(Fib
er)
PrimaryController
KCCS Standard FIC
File Server/
ADSP
Trend
Server
I/O Server
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I/O Server
2
I/O Server
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Primary Servers (LCC 1P9)
File Server/
ADSR
Trend
Server
I/O Server
1
I/O Server
2
I/O Server
3
Redundant Servers (LCC 1P9)
UPS
ATS
Generators
Analogs
Contacts
Contacts/Analogs
O2 Deficiency Monitors
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Architecture for Utility System is similar, but with 1 redundant I/O server set and end items would be AHUs, Pumps, Chillers, etc.
UtilityNetwork
DisplayClient
SGS EMOHQ
Secure KSC Industrial Ethernet Backbone (Fiber)
DisplayClient
NASA PHOSB 5th
LOAD LOAD
Smart Substation Interface
Secure KSC Industrial Ethernet Backbone (Fiber)
DisplayClient
SGS ShopK61446
DisplayClient
USA Shopk7569
Power Meter SrvC5 Substation
C5 EPPWonderware Workstation
PowerLinkControllable
Breakers(Lighting and Small Motors)
Reference #1 - NASA (Installed in 1998)
Power System Supervisory & Control Screen
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Reference #1 - NASA (Installed in 1998)
UPS System Supervisory & Control Screen
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Reference #1 - NASA (Installed in 1998)
Chilled Water System Supervisory & Control Screen
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Reference #1 - NASA (Installed in 1998)
Air Handler System Supervisory & Control Screen
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Reference #1 - NASA (Installed in 1998)
Utility Shop Overview -Supervisory & Control Screen
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Reference #2 -Mori Towers Solution Overview(Installed 2008)
Facility-wide Monitoring, Control & Reporting
• HVAC• Lighting• Energy Management (WAGES)• Reporting• Fire and Security
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• Fire and Security• Equipment / Activity scheduling
Requires strong communicationcapabilities to the Building Automation
sub-systems, and an integratedScheduler
Reference #2 -Mori Towers (Installed 2008)
Visualization - OverviewEasily identify poor tenant behaviour
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Reference #2 -Mori Towers (Installed 2008)
Visualization – Floor PlanStatus ‘hot-spots’ to display details
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Reference #2 -Mori Towers (Installed 2008)
Control Status ‘hot-spots’ to access equipment details and controls
Manage HVAC parameters
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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.
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Questions?
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