Reviewer details
Name: Details withheld at reviewer request
Product details
Vendor: Rockwell Automation
Product(s): FactoryTalk View SE
Phone: +27 (11) 654 9700
E-mail: [email protected]
URL: www.rockwellautomation.com
Application
Industry: Mining and metallurgical
Server OS: MS Server 2005
Client OS: Windows XP Pro
Front end: 15*Rockwell ControlLogix processors
Tag count: 50 000
Updates per day: Approximately 155 million and expected to increase to about 180 million
General
Q: Briefly describe the application including information on any pre-existing system that was in place.
A: This project was a greenfields project for QIT Madagascar Minerals (QMM) in southern Madagascar.
Q: Who performed the scada configuration?
A: Hatch C&I group.
Q: Approximately how many man-hours did the scada configuration take?
A: 320 man-hours for all the plant systems over an eight month period.
Q: Was a structured process followed to determine expected performance under full load and during abnormal failure conditions?
A: For data security the decision was made to configure the data servers for store and forwarding. This works very well and was very easily configured.
Q: What sort of licensing agreement applies to this particular system?
A: The system has a single licence that covers all of the application modules. Licensing is administrated via FactoryTalk SOA Platform.
Q: What upgrade agreements are in place? Are patches and version upgrades free, covered under annual maintenance or managed in some other way?
A: The end user has a parts management contract with Rockwell Automation that includes software upgrades.
Q: How is after-sales support handled?
A: Remote dial-up is available but there are suitably qualified resources onsite.
System architecture
Q: What impresses you most about the architecture?
A: The integrated architecture of FactoryTalk and the Vantage Point MIS and the ease with which they combine into an integrated platform from PLC I/O and drives upwards.
Q: What are the key physical communication layers and communication protocols employed in the system?
A: Mainly Ethernet and a mining dredger with ControlNet. A combination of copper and fibre media was used: fibre was chosen for distances longer than 500 metres. Communications to the dredger is wireless Ethernet using ALvarion radios.
Q: Is the scada system integrated onto an intranet or the Internet? If so, what level of remote monitoring and control is configured?
A: QMM policy is not to enable access to production computers from any external source. There is no intranet or Internet connectivity to this layer. There is, however, access to data using a secure connection to the VantagePoint server through a firewall.
Q: Does the application utilise web services?
A: VantagePoint provides a web-based reporting system that connects disparate data sources via web services and unites the relevant information within a single user interface.
Q: What redundancy is incorporated in this scada application?
A: There is no redundancy.
Graphics
Q: Describe the graphics development process.
A: The Hatch engineers developed blocks that connected to ControlLogix add-on instructions.
Q: How would you describe the library of graphic images?
A: The library is comprehensive and Rockwell Automation also has a website with additional resources for SIs.
Q: What human factors were taken into consideration in the HMI design process?
A: The use of standard colour templates to assist the operator in easily identifying process abnormalities.
Q: Did you use any ‘special’ images or video technology?
A: No.
Compatibility
Q: Do you run the scada in conjunction with any third-party application software?
A: No.
Q: Was any custom code or scada scripting written for this project?
A: The application made use of standard scripting that comes with the application.
Management reporting and integration
Q: Is a trending and historical data reporting system included?
A: This is included but QMM made use of FactoryTalk Historian with trending and reporting tools in FactoryTalk VantagePoint.
Q: Is a management reporting system included in the package?
A: Yes.
Q: Is the system integrated with an MES / ERP or other management reporting or control system?
A: Yes. QMM has commissioned a full MIS that is integrated with SAP. This is achieved by reading data from ControlLogix and validating it in a CSense engine. After validation it passes through the FactoryTalk Transaction Manager, which stores it in a SQL database. The data collector passes the data on to a remote central SAP server using xMII (xApp Manufacturing Integration and Intelligence).
Q: Who performed this integration?
A: The MIS was developed and commissioned by Rockwell Automation and a Madagascar system integrator.
Q: Was any additional software development needed?
A: Refer above.
Q: Are any production benchmarking tools configured as part of the scada system?
A: FactoryTalk provides benchmarking.
Q: Does the application include asset management functionality?
A: Yes, through FactoryTalk AssetCentre.
Q: Does the application include GIS (Geographic Information Systems) integration?
A: A third party mapping system has been embedded in the HMI for display of a mining ore body to the dredger operator.
System safety, security and data protection
Q: What alarm management standards or best practices were adopted in configuring the scada system?
A: Alarming is handled through the Logix PAC.
Q: How were the potential consequences of abnormal process conditions taken into consideration during the HMI design process?
A: Due consideration was given to potential alarm flooding during the design process.
Q: Does the design make provision for a DMZ and firewall segregation of process network and business networks?
A: The plant network has a private domain isolated from the outside world through a firewall. The only access from the outside is through the corporate security systems and onto an additional layer of process control software. AssetCentre monitors all changes to and security of PLCs and provides change management control.
Q: What intrusion detection is incorporated on the plant network(s) on which this scada system exists?
A: Unknown.
Q: What configuration backup and archive backup methodologies have been adopted?
A: AssetCentre maintains up-to-date backups of all FactoryTalk components including the PLC, scada, drives and network configuration files.
Conclusion
Q: What was the predominant feature(s) that made you decide to employ this scada, rather than another?
A: The ability to develop applications that fit within a suite of products was the primary feature.
Q: What impresses you the most about the system?
A: The integrated architecture and FactoryTalk SOA.
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