Reviewer details
Name: Charles Naudé
Position/designation: Architect, Process Automation Solutions
Telephone: +27 (0)16 889 2331
E-mail: [email protected]
Product details
Vendor: Rockwell Automation
Product name and version: RSView SE
Company: Mittal Steel South Africa
Telephone: +27 (0)11 654 9700
E-mail: [email protected]
URL: www.rockwellautomation.co.za
General
Q: In what industry is the scada application?
A: The metals industry.
Q: Briefly describe the application including information on any pre-existing control system or scada system that was in place.
A: An RSView SE realtime display system was deployed to consolidate existing multiple standalone scada into a unified distributed server and multiple client architecture.
Q: Who performed the scada configuration?
A: Rockwell Automation audited the concept and the process automation system integrator deployed the system.
Q: Approximately how many man-hours did the scada configuration take?
A: The tag server and Factory Talk directory with workgroup setup took ±9 man-hours. The engineering station (View studio) and CLX configuration software took less than 1 man-hour. The first client platform application software took 3 man-hours including the training accompanying the security and deployment. Subsequent clients took a short period to set-up. The most time consuming item was to get the Windows XP service-pack 2 installed, the securities set-up and the networks configured.
Q: What sort of licensing agreement is used on this particular system?
A: The system's capacity is based on a screen count package for the tag server and a development studio package. Each client required a separate licence.
Q: What upgrade agreements are in place? Are patches and version upgrades free, covered under annual maintenance or managed in some other way?
A: While under TechConnect support, downloading the patches is free.
Q: Describe how the after-sales support is handled?
A: A direct international 24/7 help desk is available via phone or e-mail. An Internet service is also offered.
System architecture
Q: How many tag points/I/O does the installation have? Analog, digital, other?
A: The scada system has a mix of more than 50 000 tags or I/O points.
Q: On what operating system is the scada running?
A: The tag server runs on Microsoft Server 2003. The studio platforms run on Server 2003, Windows XP Pro and Windows 2000 SP2. Clients run on Windows XP Pro and Windows 2000 SP2.
Q: What impresses you most about the architecture?
A: The total integration into the Level 1 environment within the global database is the most significant value-adding feature and open standard compliance regarding communication is excellent.
Q: What are the key physical communication layers and communication protocols employed in the system?
A: Most of the deployed systems are based on Ethernet communication media and protocols, but some are operating on ControlNet. The installation environment determines the use of single- or multimode fibre, as well as UTP or STP cables. Frequency hopping wireless Ethernet communication is used on long range moving equipment.
Q: Is the scada system integrated onto an intranet or the Internet?
A: No. Specific subsets of data are passed on to a plant-centric historian or required model servers.
Q: Does the application utilise web services?
A: No.
Q: What sort of redundancy is incorporated in this scada application?
A: On the communication layer, a mix of trunking and ring topology provide for multiple backup routes. Dual tag servers are deployed with primary and secondary OPC links.
Graphics
Q: Describe the graphics development process.
A: The tested graphic screens were redeployed on the field units without requiring any re-engineering. The supplied templates for placeholder pop-ups saved many man-hours during development.
Q: How would you describe the library of graphic images?
A: Standard as with all scada systems.
Q: Did you use any 'special' images?
A: The plant aerial photograph is used as the main-menu screen with target points to navigate and indicate plant area disturbances.
Compatibility
Q: Do you run the scada in conjunction with any third-party application software?
A: No.
Q: Describe any specific scada scripts or custom codes that were written for this project.
A: NA.
Management reporting and integration
Q: Is a trending and historical data reporting system included?
A: Free selection realtime trends with a 48-hour history window are deployed. Longer trends (three years) are displayed by the system via an Active-X window from the plant-centric historian system.
Q: Is a management reporting system included in the package?
A: Not implemented due to company standardisation of reporting. Simple totalising shift reports are generated by the scada.
Q: Is the system integrated with an MES/ERP or other management reporting or control system? If so then please describe the integration process and methodology.
A: Yes via the plant-centric historian system.
Q: Who performed this integration?
A: In-house deployment.
Q: Was any additional software development needed?
A: No the tag servers fully comply with OPC 2.
Q: Describe any production benchmarking tools which have been configured as part of the scada system?
A: None were implemented.
System safety, security and data protection
Q: Describe any alarm management standards or best practices that have been adopted in configuring the scada system.
A: Used GAMP 4 and 'Alarm Systems, a guide to design, management and procurement', Engineering Equipment & Materials Users Association (EEMUA) Publication No 191 as guidelines during engineering.
Q: What steps have been taken to firewall the plant network(s) on which this scada system exists?
A: Separate isolated plant network system. Multiple network interface cards in the tag servers with plant-centric firewall equipment on the level 2 networks.
Q: What intrusion detection has been incorporated on the plant network(s) on which this scada system exists?
A: None yet.
Q: Describe any configuration and archive backup methodologies that you used.
A: RSMACC has been deployed as a single point of Authentication Security (encryption), Audit trail and Backup system.
Conclusion
Q: What impresses you the most about the system?
A: Total integration, re-use of other project templates, scalability and one user interface for developing small applications into very large applications.
Q: What predominant features made you decide to employ this scada, rather than another?
A: This scada system was selected as part of a vertical best of breed structure, rather than horizontal best of breed structure, to gain all the benefits of integration. On a horizontal comparison it would have most probably been selected for the distributed architecture. Client Server.
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