Dave Wibberley CEO Adroit Technologies
• Adroit Technologies Company • SCADA References• MAPS SCADA• Alarm Management and Analysis• Adroit SCADA Intelligence • MAPS Process Suite• Closing
AGENDA
ADROIT TECHNOLOGIES COMPANY OVERVIEW
• Integrity• Excellence in Customer Service• Value• Creativity• Social Responsibility
ADROIT TECHNOLOGIES – CORE VALUES
ADROIT TECHNOLOGIES – THE COMPANY
South African Software Company, Mitsubishi Factory Automation Supplier for Sub-Saharan Africa Mitsubishi Electric own 14.9% of the shares of Adroit Technologies
Been developing real-time SCADA software for more than 25 years•Employs around 70 people•Global supplier in 5 continents, 14 countries •European Mitsubishi Software Partner•Over 15000 Licensed Seats, more than a 1500 unique customers worldwide.
.
More than 400 SCADA systems in Europe
•Petrochemical
•Pulp and Paper
•Food and Beverage
•Energy Management
•Building Management
•Water Treatment/Distribution
•Agriculture
INDUSTRIES AND APPLICATIONS
•Power Utilities
•Nuclear
•Cement
•Automotive
•Mining
•Oil and Gas
•Telecommunications
ADROIT SCADA/HMI MARKETS
MAPS / MAPS SCADA HMI
OPERATIONAL ANALYSISAND SCADA SYSTEM REPORTING
ENTERPRISE REPORTING
ADROIT TECHNOLOGIES PRODUCTS AND SOLUTIONS
SOME REFERENCES
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- Dia
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dsAfrica – Botswana - Debswana Mining Group – Mining
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- Cop
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Africa – Botswana - African Copper – Mining
Europe - Mining Equipment OEM - Sandvik M
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g - O
ther
Europe - Minsk Water - Belorussia - Water
Africa – Data Centre Facility Management
Africa – Pretoria Portland Cement – Cement Production
Europe – Megadrive Automation - Gibraltar – Ship Control System
MAPS Supervisory Control and Data Acquisition (MAPS SCADA)
MAPS SCADA / HMI SOFTWARE
Benefits of using MAPS• Built on 25 years of experience • Real Time Software (No compilation, Online Configuration) • Flexible Object Oriented• Client Server Architecture• Most internal Agents included – only pay for scanned I/O• Driver Library of over 100 front-end devices included
MAPS SCADA / HMI SOFTWAREAdd power and resources as required•Scalable Product Range - 30, 75, 150, 300, 750, 1500, 2500, 5000, 25000, System Limited Scan Points. If you need to upgrade, pay the difference•Various configurations available: - Stand Alone
- Distributed Architecture- Redundant Active Clustering
Group and Site Wide Licensing Agreements
MAPS SCADA – I/O SERVER OPENNESS
MAPS Agent
Server (I/O Server)
OLE Automation
Excel, Word, VB etc
ActiveX Object
Embed in Applications
C++ API
Internal Server Side
Scripting – VB Script/Java
OPC Server
• Some Functions Supported– Add Tag– Delete Tag– Get Value of Tag– Set Value of Tag– Get History of Tag– Scan/Alarm Tag
MAPS STAND ALONE ARCHITECTURE
Ethernet TCP/IPCommunication
Designer/Operator and Agent (I/O) Server On same machine
MAPS HOT STANDBY ARCHITECTURE
Ethernet TCP/IPCommunication
MAPS Operator MAPS Operator
MAPS DISTRIBUTED ARCHITECTURE
MAPS SCADA - ARCHITECTUREMAPS Designer
MAPS Graphic and Data Server
Agent Server
MAPS Operator
MAPS Agent (I/O) Server
Agents / Tag DatabaseScanningLoggingAlarm
MAPS AGENT SERVER – AGENT DEFINITION
Agent (I/O)
Server
Basic Agents•Analogue•Digital• String
Advanced Agents•OEE
•Counter•DB Access
• Scripting etc
System• System Information
•HASP (license)•Device• Scan
User Defined •UDT
•Custom
More than 45 different Agent types
MAPS AGENT SERVER – AGENT DEFINITION
Agents are called Agents because, instead of only containing data, like simple database records, they also usually contain the ability to operate or act on their own data, driving its values and to read and write to other objects, and so influence them.
This concept is very much in line with object-oriented thinking, and is primarily why we refer to Adroit as being "object-oriented".
OBJECT BASED TECHNOLOGY
•All Agents are Intelligent Objects – contain state information, behaviours and action (combined sum of conditions)•Custom Agents – Build own objects to represent plant items and equipment•User Defined Types (UDT depends on protocol support)•Each Agent type is a Dynamic Link Library (DLL)
BASIC AGENTS - DIGITAL
Agent Type – Digital
Agent Name – DIG01
Properties Available
Description - DIG01.agentdescriptionValue - DIG01.valueTextValue – DIG01.textvalue
BASIC AGENTS - ANALOGUE
ADVANCED AGENTS
MES/MIS Capabilities within standard SCADA product•Scripting Agents•DBAcess Agents•Counter Agent•Statistical Agent•Max Demand Monitoring Agent •OEE/KPI Agent•Shift Agent
Counter AgentPreventative maintenance & downtime management
Statistical AgentThe Statistical agent provides the basic functionality for a user to build a statistical process control strategy using its built in data collection method and by linking to other internal agents.
DBAcess Agent Benefits from using this Agent
• Connect to most known databases using OLEDB compliant databases• Update Data in Tables• Read Data from Tables• Delete Data in Tables• Retrieve Data from Tables
Transact based on time, trigger tagor both
Ideal for Production, Recipe, Batching Systems
OEE / KPI Agent – Standard in Product Benefits from using this Agent•Measure Overall Equipment Effectiveness (Availability X Performance X Quality)•Measure two KPI values against one another (Tons/hr)
Ideal for Production Performance Management
MAPS Data Logging Advanced logging – local historian and/or SQL
•ODBC/OLE DB – Bi-directional connectivity to external databases though our OLE DB Datasource•Adroit historical logs (.LGD) - data from all Adroit historical logs can be extracted in a Comma Separated Variable (CSV) format•Log Sets - Multiple Log Sets and resolution possible•DB Access Agent (Recipe Handling Example)•DB Log Agent (SCADA Reporting Data Format)•No Scripting or SQL Queries required
Flexible Alarming • Global and Local Alarm Acknowledgement• Custom Alarm Types (Intruder, Scan Inhibited etc.)• Alarm Routes and Lists (Configure Alarm Hierarchies)• Delays• Conditional expressions • Log Alarm/Event to SQL• Audio devices• SMS• Email • Priority Levels
Trending• View historical and real time values• Unlimited pens per window• Print to file or printer• Export to Excel, XML, HTML• Importing of historical trend data
Adroit SecurityAdvanced security•Uses native Windows security model (Active Directory) - Apply security through existing users and groups•All elements are “locked down” until user rights are assigned•Policies – Configurable set of rules for large scale control •Security applied at 3 levels - Server (Allowed users and groups) - Clients (Profile determines available menus) - Data Source to element level (Read, Write, Remove)
MAPS DESIGNER
Benefits from using this product
Easy and Intuitive InterfaceCombine vectors and controls to build HMI graphicsMore than 300 graphical objectsWizards and Templates – minimise engineering timeAdd 3rd Party Controls – ActiveX or Windows Controls, WPFConfiguration rather than scripting
MAPS – CLIENT APPLICATION – DESIGNER AND OPERATOR
Benefits from using this product• Secure and easy access to disparate data sources – OPC, Adroit, Web Services, OLEDB• Easy collaboration between different data sources and types• Familiar Windows forms based design environment• Internet enabled communications• Integration in Visual Studio for form based scripting• Central management and auto-deployment of the application• Multiple language support ideal for OEM’s
Africa – Pretoria Portland Cement – Cement Production
MAPS IS NOT AN EVOLUTION – IT’S A REVOLUTION
MAPS - MITSUBISHI ADROIT PROCESS SUITE
What is MAPS?MAPS is a collaboration between Adroit Technologies and Mitsubishi focused around offering an integrated PLC/SCADA programming and management tool.
The result is an integrated life-cycle management solution to the automation industry.
MAPS FEATURES
Benefits from using this product
• Drawings, documentation and changes made are kept synchronized and up to date• Built in .NET the final solution offers web-enabled capacity• Uses ISA 88/95 Standards and pre-defined IEC Function Blocks
• Single point of configuration• On-going life cycle management• Automatically generated PLC and SCADA projects• Automatically generated reports• Automatically generated management screens
MAPS
SCADA functionality delivered with MAPS•All tags associated with FB’s •All mimics in structured format containing selected graphic objects. •Logging, Alarming and Trending set-up using templates •The ability to add custom mimics in the same structured hierarchy •Each graphic object has associated faceplates to deliver further management capability
Fully integrated SCADA, PLC solution based on the well proven Mitsubishi PLC and Adroit SCADA system
CO-ORDINATED PLC FB’s AND SCADA GRAPHICS• Standard faceplate• Setup • Alarms & Events• Trends
Auto Generate all Graphics and Faceplates for Control, Alarming, Simulation and Maintenance
Focus on cost reduction and return on investment (ROI)• Excel based import & export assistant – included as standard in MAPS to reduce design costs by up to 30%
Fully integrated SCADA, PLC solution based on the well proven Mitsubishi PLC and Adroit SCADA system
Auto Generate all the PLC Function Blocks, SCADA database and PLC-SCADA Communication
Fully integrated SCADA, PLC solution based on the well proven Mitsubishi PLC and Adroit SCADA system
Auto Generate all Graphics, Navigation and Faceplates for Control, Alarming, Simulation and Maintenance
Diagnostic features
in MAPS
Integrated diagnostics and maintenance tools
Auto Generate Diagnostics and Access to PLC code from MAPS Designer
Integrated diagnostics and maintenance tools
Launch PLC diagnostics from MAPS Designer
Reporting and Documentation
in MAPS
Reporting and Documentation - Project Report
All reports fully customisable
All reports fully customisable
Reporting and Documentation – PLC and IO report
Adroit Alarm Management and Analysis - AMA
AMA (Alarm Management and Analysis)
Benefits from using this product• Improved Productivity• Improved Performance• Better Decision Making around Asset
Management• Distinguish between Alarms and
Events • All reports based on ISA 18.02,
EEMUA 191• Ease of Use
Alarm System Terminology
An Alarm is an event to which an operator must react, respond and acknowledge.
An Alarm System is there to prevent, or at least minimize, physical and economic loss through operator intervention in response to the condition that was alarmed on any given process.
Secondly, an Alarm System should provide and alarm and event log.
Current Problems
• Alarm flooding during plant upset• Too many standing alarms – accepted as ‘normal’• Too many ‘high’ priority alarms• Lack of real information to support decision making
Consequences
Operators presented with too many alarms may overlook an important indicator of an abnormal situation, or be so overwhelmed as to unnecessarily trip the unit as a safety measure instead of trying to decipher the information being conveyed.
Both scenarios can significantly impact the safety of plant personnel and the efficiency of plant operations.
Benefits of using AMA• Measure and improve Alarm System Performance• Analyse historical alarms
– Highlight unwanted / unnecessary alarms– Highlight problem areas in the plant
• Analyse alarms and associated process variables• Monitor operator alarm interaction• Valuable part of an alarm management strategy
Adroit Alarm Management Agent
• Licensed component of an Adroit agent server• Route new and existing Adroit alarms to a SQL database• Categorise alarms
• Assign associated process values for alarms• Set performance KPI targets• Database housekeeping
• Configure pre-defined Reasons for operator input on specified alarms
• Link documents to alarms (e.g. SOPs)• Multiple Adroit agent servers can connect to a single Alarm
Management database• Bulk configuration with Excel import / export
Adroit Alarm Management Agent
Adroit Alarming to improve performance
• Create custom alarm types• Suppress nuisance alarms
– Alarm delays– Conditional alarming
• Alarm inhibiting• Alarm prioritisation
Alarm Report Features• Reports are Web based – no client side installs• Report drill through from summaries to detail• Help documentation available on reports• Open technology platform for users to create custom
reports
Report Builder for report development
Alarm Report Features• Export reports to Excel, Word or PDF• Report scheduling (not with SQL Express)• Report Printing• Microsoft Active Directory Security
Alarm System Performance• Alarm System Performance dashboard
• Performance comparison between periods
Alarm Analysis• Bad Actors
– By alarm type– By category– Intermittent alarms– Stale alarms– Most frequent alarm
• Alarm Types• Alarm Categories
• Process variables can be associated to an alarm
• Reasons and sub-reasons can be captured against alarms
Associated Process Values and Reasons
Associated process value when incident occurred
Icon shows Reasons and Notes for alarm with drill through
Tooltip shows details
Operator Performance• Alarms acknowledged in time• List alarms not acknowledged in time
• Acknowledged incidents per hour
Performance Comparison Report
Bad Actors Report
Alarm Category Report
Reasons and Notes Analysis
Incident Detail Report
Reporting and Analysis of SCADA data made easy
Challenges with SCADA / PLC Data• Unstructured with no business context• Data requires processing• Huge amounts of data to manage• Difficult to extract, process and present the data in reports• Difficult to analyse
Challenges – Relational database• Relational design is very specific to each reporting solution• SQL skills required to design the database • Data insertion is more complex• Must understand relationships to retrieve data
Adroit SCADA Intelligence (ASI)ASI is data warehousing system which collects and processes data from disparate data sources and makes the resulting information available on a common platform to enable decision making.
SCADA Intelligence Architecture
ISA 88/95Enterprise
Site
Area
Process Cell
Unit
Production Unit
Unit
Production Line
Work Cell
Storage Zone
Storage Unit
Batch Production
Work CentresWork Units
Continuous Production
Discrete Production
Storage or Movement
Equipment Module
Control Module
ASI Manager – System Configuration
Analog Compliance• Define Limits
– Control &– Specification
• Compliance Summaries– % In Control– % In Specification
• Drive exception based reports
Analysis – using Microsoft Excel
Machine Availability Scorecard
Production Summary Report
Production Summary
Production Summary - Conveyor Inline Scale
Conveyors Production Dashboard
Conveyor Daily Production Report
Conveyors Utilisation and Loading Efficiency Dashboard
Environmental – Airflow Dashboard
Environmental - Air Quality Scorecard
Cost Benefit Analysis of ASI
Report Implementation Challenges
• Difficult to scope report requirements• Difficult to quote on reporting solutions• Databases require on-going maintenance• The system must be able to grow with
changing user requirements
TRADITIONAL REPORTING SOLUTION
Software
SQL 2008 R2 Standard Edition (5 CALS) 20 000
20 000
Engineering
User Requirement Specification 24 000
Database design and development 60 000
System and Tag Configuration 12 000
Report Development 42 000
Database Integrity tests 18 000
Report Integrity tests 18 000
On-site installation 6 000
Final Documentation 12 000
192 000
Total Cost 212 000
Software9%
Engineering91%
Cost Breakdown
SCADA INTELLIGENCE – CUSTOM REPORTS
SoftwareAdroit SCADA Intelligence (150 Items) 58 000
SQL 2008 R2 Ent. Runtime Edition (5 CALS) 15 000
73 000
Engineering
User Requirement Specification 24 000
Database design and development -
System and Tag Configuration 12 000
Report Development 30 000
Database Integrity tests -
Report Integrity tests 18 000
On-site installation 6 000
Final Documentation 6 000
96 000
Total Cost 169 000
Software34%
Engineering45%
Cost Saving20%
Cost Breakdown
SCADA INTELLIGENCE – REPORT PACKS
Software
Adroit SCADA Intelligence (150 Items) 58 000
SQL 2008 R2 Ent. Runtime Edition (5 CALS) 15 000
73 000
Engineering
User Requirement Specification -
Database design and development -
System and Tag Configuration 12 000
Report Development -
Database Integrity tests -
Report Integrity tests 12 000
On-site installation 6 000
Final Documentation -
30 000
Total Cost 103 000
Software34%
Engineer-ing
14%
Cost Saving51%
Cost Breakdown
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