Retailer Trends in Distributed Controls and Electronics · A Unifying Layer for Centralized & Distributed Systems •Enterprise software is required---independent of the control architecture

Retailer Trends in Distributed Controls

and Electronics

E360 Forum • Houston, TX • October 25, 2018

Ron Chapek

Director, Product Management — Enterprise Software

Emerson

John Wallace

Director of Innovation

Emerson

Discussion Topics

IntroductionWhat’s the

difference?

Distributed

vs.

central

(or both)

What do I

need to plan

for in the

future?

Background and

evolution of control

systems

What are the different

architecture “layers” of

a control system?

What are the key

differences and similarities

of the different control

architectures? What

are the benefits?

Is it possible to “future

proof” my systems?

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Definitions

• Slight differences in meaning across industries

• Generally, BAS implies broader integration, while EMS implies focus on energy management

• Refers to a collection of hardware and software to monitor and control the mechanical, electronic and lighting systems

• Installed at a single site

• For our purposes, these are the same thing

Energy Management

System (EMS)

Building Automation

System (BAS)

Facility Management

System (FMS)

Building

Management

System (BMS)

3

Systems Evolved From “Islands of Control” to Form a Complete

Integrated Control System

• Individual systems tied together

• Information sharing across systems

• Emergence of “supervisory functions”

• Integration/control maturity similar to auto industry evolution

– Communication technologies

– More sensors

– Smarter control

– Use data to drive actions

Supervisory

system

HVAC

LightingREF

Other

Connecting the “islands” into

an integrated control system

Evolution and progress

4

Layers and Functions of a Control System

Remote

Supervisory

Control

• Remote user interface

• Site information

• Data feed

Key elementsArchitecture layer

• On-site user interface

• User management

• Data logging

• Alarming

• Cross-system coordination

• Control algorithms

• Inputs and outputs

• Sensors and transducers

• Equipment interface

Hardware Can Be

Combined or Separated

Site

5

Integration and Communication Capability Key Part of BMS

Benefits• Common user interface across site

• Remote access

• Normalized information (alarms, logs, etc.) using operational visibility

Core

HVACR/L

BMS

Supervisory layer

normalizes information

to provide alarms,

data logs, etc.

53%

6%

41%

HVAC REFR OTHER

Third

Party

Devices

70%

27%

3%

ECHELON MODBUS BACNET

By protocolBy type

Third Party Device Statistics

Note: Statistics based on Emerson’s E2 support

Water heaters, energy

meters, car chargers,

breaker panels, etc.

6

Distributed Control Systems — The Technical Definition

7

Source: Wikipedia https://en.wikipedia.org/wiki/Distributed_control_system

John’s definition:

push control intelligence

down to the “edge” while

pushing monitoring and

supervisory functions “up”

Distributed vs. Central: A Familiar Example

8

Centralized control

• Control algorithms run in centralized E2

• I/O boards utilized for inputs, relays

Distributed control

• Control algorithms run in distributed controllers

• Communication to E2 or Site Supervisor for

supervisory functions

John’s definition:

push control intelligence

down to the “edge” while

pushing monitoring and

supervisory functions “up”

Comparison of Refrigeration Control Architectures

Floorplan

Refr.

controls

• Control elements centralized at refrigeration

rack or electrical panel

• “Home runs” for sensors

• “I/O” boards for control

• Control elements at case

• Communication “daisy chain” to EMS

• Complete control at refrigeration case

• Case electronics for control

Case

controls

Case

controls

Refr.

controls

Centralized control architecture Distributed control architecture

Case

controls

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Distributed Control Benefits

• OEM/equipment providers can factory install and test to deliver a complete working system

• Broader integration delivers more value to end user

• Reduced field wiring and startup time

• Technology flexibility allows best “fit” solution

• Additional sensors provide more data for remote troubleshooting

• Lifecycle cost advantage

Lifecycle cost considerations for distributed case control

Sensors feed data analytics to facilitate cost optimization

11

Planning for the Future: Newer Systems Need Flexibility and

Advanced Control to Create Smarter Buildings

• “Traditional” control architecture

expanding to enable more value

• Flexibility provided by add-on “apps”

which facilitate customized solutions

• Site control provides macro-level

control, coordination of equipment on a

cross-site basis (i.e., HVAC/R) and

data aggregation

• Transactive services provide

opportunity to utilize “smart grid” as

well as other cloud-based services

(i.e., renewable integration, etc.)

12

Supervisory

Equipment control

Site control

Transactive

services

Apps

Remote Cloud services Transactive

services

Distributed controllers

Advanced BMS

Future Case Example: Using Data and Machine

Learning to Optimize Site Control

13

Supervisory

System Collects

Performance

Data From

Equipment

Controls

Selected Data

Provided to

Cloud-Based Service

Cloud-Based

Data Analysis and AI/Machine Learning

Optimized

Performance

Model

Site-Level Control

Updated Automatically to

Optimize Performance

Integration Between Site Controls and Cloud-

Based Services Key to Performance OptimizationSite-Level Control and

Supervisory System

Model Created

Based on

Site/Enterprise Data

Discussion Summary and Questions

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• Global trends driving distributed control architecture transition

• Hybrid systems (i.e., case controllers with centralized rack control) are common and familiar

• Benefits include factory test, reduced startups and potentially lower lifecycle costs

• System integration capabilities as well as domain expertise keys to seamless transition and creation of integrated solution

• Advanced capabilities (cloud, transitive, machine learning, etc.) drive need for advanced, flexible BMS which can be utilized with distributed controls

• Closely coupled integration between site and cloud creates opportunities for optimization

John’s definition:

push control intelligence

down to the “edge” while

pushing monitoring and

supervisory functions “up”

Enterprise-level

Software

Enterprise-level SoftwareMacro Trends for Multisite Retail

• Adoption of cloud-based building/asset/energy solutions

• Deployment of IP-enabled devices (IoT)

• Exponential increase in data volumes

• Aggregation of multiple, previously disparate data sources

• Adoption of Master Data Management/MDM

• Proliferation and adoption of dashboarding, analytics and reporting apps

• Rapid customization of user-experience (Persona-specific)

• Integration of refrigeration/HVAC/lighting with other enterprise platforms

• Need for a single platform with a single user-interface (Common UI/UX)

• Future-proofing platforms to meet rapidly-morphing requirements

Trends are Increasing the Need for Enterprise-level Software

Enterprise-level SoftwareProblem/Solution Statement

• Enterprise software provides data-driven, persona-specific solutions that actively monitor & control site-level assets across their enterprise from a central location.

– Value is delivered by providing real-time visibility, management, analysis/reporting plus ADMIN and other system-level functions

• Controller Access Control

• Controller Backup/Firmware Management

• Alarm/Setpoint/Energy Management

• Refrigerant Compliance

• Maintenance Management

“I Need Help Getting and Staying Ahead of My Complex Enterprise….”

Enterprise-level SoftwareA Unifying Layer for Centralized & Distributed Systems

• Enterprise software is required---independent of the control architecture

– Data is aggregated locally (site) where real-time control is executed and then moved to the cloud

– Non-real-time analysis/reporting is executed at the Data Management/Presentation layer

• Same-day and day+1

– Predictive maintenance with root-cause identification

• Weekly/monthly

– Trend analysis

• Year/multi-year archiving

– Modeling & audit/compliance

Value Originates at the Device/IoT-layer & Delivered at the Presentation-layer

Enterprise-level SoftwareVisualizations are Solution-specific

• Provide only required information

– Apply comprehensive filtering criteria

• Time, data-type, asset-type, location, limits, etc.

• Provide highly graphical, intuitive views

– Expand adoption to include non-domain experts

• Complete specific use-cases

– Color-coded map-view of sites with two-click navigation to ID root-cause

• Include prescriptive corrective action(s)

The User-experience Now Tailored to Specific Personas/Tasks

Enterprise-level SoftwarePerformance/Responsiveness at-Scale

• Centrally manage 10s/100s/1000s sites

– Simultaneous updates (500 sites)

• Global device completed in hours not days

• Push menu changes to smart kitchen devices

• Make as-needed firmware updates

– Load graphics e.g. floor-plans in seconds

• Near real-time updates for critical values e.g. case temperatures

– Actively manage site/asset-level alarms

• Automatically prioritize and triage events

– Faster root-cause analysis and resolution

• Requires integration with service software

Complete Global Changes in Hours Instead of Days

Enterprise-level Software Example Three: Setpoint Benchmarks & Changes

Maintaining Setpoints Optimizes Asset Performance & Energy Savings

Advisory Status Map provides global and

regional views of alarming sites helping

to identify problem sites/assets.

Color coding of site active alarms

provides indication of alarm intensity.

Snapshot summary of site Active and

Return-to-Normal Advisory counts with

links to Advisory details or Device UI.

1

2

3

1

2

3

Enterprise-level SoftwareExample One: Advisory Status Map

At-a-Glance Overview of Enterprise Status/Health

Site floor plan provides simple

view of cabinets location and

current temperatures and status.

1

2

3 Click on cabinet color to view

graphical details of coil, fans,

doors live state and values.

Click on temperatures provides

quick graph and details of alarm

and defrost settings.

Enterprise-level Software Example Two: Floor Plan with Link to Asset Data

1

3

2

Identify, Diagnose and Resolve Asset-level Issues--Faster

Enterprise-level SoftwareOpen Architecture “At the Top”

• Leverage APIs to provide specific data for analysis & reporting plus niche applications– What points?

– What rate?

– What throughput?

– What priority?

• Governed/managed data access – Control remains the highest priority

– System stability trumps data-transfer

• Microservices execute on separate servers – Enterprise application is mission critical

(requires dedicated resources)

Sharing Data at the Enterprise-layer Provides Low-Risk Data Access

Microservices (API) Architecture

• ISO27001 Certified Data Center

• Full Disaster Recovery Capabilities

• 24x7x365 System Monitoring/Incident Resolution

• 24x7 Incident Response

• Enterprise Crisis Management Plans In-place

• Security Team CISSP Certified

• Network Team Cisco Certified

• Web Application Firewall

• Hardware and Operating System Updates

Off-premise Data/System Hosting Increasingly Adopted

Enterprise-level SoftwareSecure Cloud-based Systems/Hosted

Questions?

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