The Challenges and Solutions to Integrate Multi-Facility/Buildings Disparate Management Systems Across a Steel Mill Plant – Dave Hreha

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

1

I/O Server

2

I/O Server

3

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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