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What amounts to right information? Information – That’s what it’s all about (2)
Information collation – putting the puzzle together
Focusing on the right aspects of Operational Performance Management Are CIOs being caught napping?
Giving people what they asked for X-CHANGE 2012 report-back
EVENTS | TECH TIPS | TRAINING | SUPPORT May/June 2012 | 1
Editor’s Notes Although this is obvious, the solution hasn’t
hugely important milestone because we now
been at all obvious until comparatively
have a process we can improve. So, what’s
recently. This is because it’s taken a
concerted effort on different fronts to make it all possible.
The immediate information future probably lies in three areas of crucial importance.
One of the main breakthroughs happened
The first is improving the level of decision
when solution vendors realised they couldn’t
support through agents like Artificial
control the market and shut out their
Intelligence and Neural Networks because,
competitors with proprietary solutions. They
in our increasingly complex and competitive
had to develop open systems and make
industrial world, it’s going to take more right
their data available to all and sundry or they
first-guesses to succeed.
would soon not even exist in the very market they tried to monopolise.
The second is applying the principles of industrial automation to the company as
Information – that’s what it’s all about (2) In the last issue of Protocol, we looked at
Another milestone event was the
a whole. Let’s measure what we’re doing
development of hardware and software
so that we can correct it at the human
(e.g. ISA-95) standards which promoted the
and corporate level. We have all these
interconnection of equipment and software
well-disciplined and controlled production
products from all vendors.
processes generating our wealth but who’s
the solutions available for the first half of
controlling them – and how? An information
the information process which dealt with the
Although hardware and software
process at the enterprise level will tell you
capturing and storage of data. In this issue
communication barriers had been breached,
all you need to know about improving the
we look at the second half of the process
this still wasn’t enough. Everything still
processes in charge of your company’s
which deals with collating the right data
had to be integrated under a common
wealth by giving them the feedback they
with the right context to provide information
umbrella. The third breakthrough came with
need to minimise guesswork, make informed
which is then disseminated to those who
the introduction of Invensys Wonderware’s
decisions in real-time and incrementally
System Platform in 2003. This rapidly
became the de facto “operating system” These are crucial processes because they
for the industrial automation industry as it
The third area of importance is probably
turn data into information. Conversely, they
was designed from the start with the needs
virtualisation and cloud computing which
could be wrongly used and turn the same
of that industry in mind. It turned out that
improves accessibility to information and
data into unwanted but great-looking noise.
it wasn’t more applications end-users were
system availability in cost-effective ways but
looking for but a unifying platform that could
more about this in a future issue.
As pointed out in the article titled “What
make full use of their past investments,
amounts to right information?” by Deon van
provide current cost-effective solutions
I hope you find this and the previous
Aardt and Ernst van Wyk, one of the main
quickly and look after their future needs – no
information issue of Protocol useful to cross-
problems with information is that it has to be
matter what they might be.
reference the information function you want
derived from a multitude of often disparate
to address with the Invensys Operations
sources for distribution to an equally wide
So, we’ve come a long way and it’s taken an
Management solutions available to help you
spectrum of users who are each interested
approach that no single vendor could have
achieve your goals.
in different aspects of a common reality.
imagined ten years ago.
Executives and operators, for example, need
Until next time,
to know different things at different times
But are our information, knowledge and
Denis du Buisson
because they will be making very dissimilar
decision-making problems over? Let’s face
decisions. But if the decisions they make are
it; it wouldn’t be fun if they were. We’ve got
based on different versions of the truth, then
most the mechanics of data collection and
we have chaos.
information dissemination licked and that’s a
2 | www.protocolmag.co.za
What amounts to “right
Plant Information Management
46 system at Petro Rabigh
Australia’s QR National chooses
9 Wonderware Intelligence
57 Invensys Rail to cope with
soaring mining freight needs
Information Collation: Wonderware QI Analyst
58 Management - Focusing on the
Information Collation: Wonderware Historian Client (previously ActiveFactory)
Are CIOs being caught napping?
60 – IT Governance and Process Automation
Information collation and
64 Information dictionary 23
Information Dissemination: Wonderware Information Server
Events – X-CHANGE 2012
28 Wonderware HMI Reports
Use Protocol Magazine to
78 generate business opportunities
33 SmartGlance and Wonderware
81 Support – Customer FIRST
38 Remote Response Objects
2012 Training Schedule
Information Dissemination: Wonderware SCADAlarm alarm and event notification software
82 On the lighter side 84 Protocol crossword # 54
Contributors Many thanks to the following for their contributions to this issue of the magazine:
Protocol Magazine Owner and Publisher: Invensys Operations Management Southern Africa
Marketing Manager: Jaco Markwat email@example.com
Editor: Denis du Buisson, GMT Services firstname.lastname@example.org
• Dr. Kobus van der Merwe of Industrial Management Enhancement for the article about focusing on the right aspects of Operational Performance Management • John Coetzee of Aristotle Consulting for the article titled: Are CIOs being caught napping? – IT Governance and Process Automation • Patrick D. Murray, Principal Engineer, Invensys and Yadukulatilakam Ramaswamy, Senior Director, Consulting Services, Invensys for their article on the Plant Information Management System at Petro Rabigh • Deon van Aardt and Ernst van Wyk of Invensys Wonderware Southern Africa for the article on what amounts to the right information?
Advertising Sales: Heather Simpkins, The Marketing Suite email@example.com
Distribution: Nikita Wagner firstname.lastname@example.org
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Wonderware Southern Africa WonderwareSA WonderwareSA
July – August 2012
17 May 2012
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September – October 2012
16 July 2012
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November – December 2012
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January – February 2013
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May/June 2012 | 3
What amounts to “right information”?
Deon van Aardt, Divisional Director - Invensys Operations Management Southern Africa
Right information is actionable information
The right context
which depends on real-time reporting and easy analysis of centralised data.
An item of data is largely meaningless unless one also knows the conditions under which it
Right information is characterised as that
was measured and to what it refers. A simple
information which is presented in the right
way of representing this is shown in figure
context to the right people at the right time
1 where what we measure is above the line
and in the right format so that they can take
and the context in which it applies is below
the right action.
the line. The result is the information we want to know.
A production facility is involved with a
Ernst van Wyk, General Manager Technology, Invensys Wonderware
4 | www.protocolmag.co.za
multitude of activities all of which generate
So, for example, we may want to know
data which have to be collected and turned
about equipment efficiency so Overall
into meaningful information. These activities
Equipment Effectiveness (OEE) goes
can include the monitoring of air, water and
above the line and “equipment” below it.
electricity usage, production and process
We can now change the context to say, the
status, equipment performance (OEE),
“plant”, which now becomes the context
alarms, waste generation as well as time and
against which efficiency is reported. We
money. Analysed in isolation of one another,
may also want to know how OEE varies
these data aren’t anywhere as informative as
with time so “time” is now made the
they could be.
context. In this way, the context can be
What amounts to “right information”?
database. Personnel might be collecting air, gas and water data manually on clipboards before logging their observations in Excel spreadsheets. Speaking of spreadsheets, they have their own set of problems: For example, to calculate wastage, the same data might have been collected by different people at different times and they may each be incomplete to varying degrees as all the data for calculation isn’t yet available. When results are finally presented, which version of the truth is to be believed? And how many man-hours did it take to get there? Is this good information? – probably not because it may be hours or even days too late to do anything about events in the plant. And what about its accuracy? All these disparate data sources are vital, Figure 1: Measuring things within context yields usable information
however, as they are all pieces of the information puzzle which, if assembled
anything of relevance in the plant (people,
means updating all relevant dashboards,
correctly, will give a realistic picture of the
batches, assets, etc.)
reports and analysis tools in real-time – no
company’s performance. So, how do we
problem at all if we’re talking about one
overcome the problem of synchronising and
The real world
collating data and information, irrespective
In an ideal world, all this information would
But this is the real world and here, things are
be available at a central location and to
very different. Electricity consumption might
anyone who needed it. When monitoring
be measured by an energy management
The Wonderware System Platform has
energy usage, for example, measuring the
system that has its own database. PLCs,
the ability of bringing all these sources of
consumption of air, gas, water and electricity
DCS or SCADA systems might be logging
information into a single system and, as we
must happen in real-time so that decisions
real-time plant equipment electricity
just saw, it’s only with a single system that
can be made in real-time but that also
consumption data for storage in a historian
real-time updates and data synchronisation
of its multiple and different sources? The answer is shown in figure 2.
of dashboards, reports and analysis tools is possible. Now that the right information is available in the right context on a single platform, the next step is to make it available to the right people at the right time and in the right format - and that means answering five fundamental questions: • Who needs to know? • What do they want to know? • Where are they? • When do they want the information? • How do they want it delivered?
Figure 2: A single system is required if data from a multitude of disparate sources are to be transformed into current, updated, accurate and contextualised real-time information.
May/June 2012 | 5
Figure 3: The information needs and delivery systems of some key plant personnel
Getting the right information to the right people so that they can take timely action
will lead him into the real-time information he can access on demand (figure 4). Here, he’s confronted with a custom-
The right people include executives, plant
designed information screen showing
Figure 6: Wherever he may be, Smartphone
managers, planning personnel, quality
enterprise-wide KPIs including production
technology can keep the production
assurance personnel, process engineers,
performance and financial status, quality
manager informed of conditions at the plant
maintenance personnel, supervisors and
consistency, maintenance records and an
operators. For the purpose of illustrating
unlimited range of other criteria important
how this is done, however, we only include
to someone in his position. Information can
company’s production status at any time
five groups as shown in figure 3.
be grouped and collated with respect to the
(including that of individual production lines)
entire enterprise, a specific site as well as the
to check if he can take on more work within
production area, process cell and unit within
the specified time constraints of a potential
that site. All the information is available
order. He might also want to check on the
He’ll probably be in his office in front of a PC
through the company Intranet so that he can
production status of their orders when
and he’ll want to know the status of the plant,
have access to it from virtually anywhere.
meeting with existing customers.
The important thing is that he isn’t swamped
The plant manager
right now. Whatever application he may be running, there will be an icon on his screen that
with irrelevant trivia so that he can focus on the decisions he will have to take.
He wants to know about any problems with the plant at any time so that he can do his
The system engineer
job of sorting things out. He too may be travelling or he could be at home. Whatever
He too might be looking at his PC in his
the case, he should only be called when
office but, apart from engineering work,
there’s no one else available to solve the
he’s only interested in events where
problem (ArchestrA Workflow software is
things have gone wrong. Unobtrusively
there for just that reason).
on the side of his screen are displayed
Figure 4: An example of the executive’s point of view
the real-time parameters of OEE and
Whether by e-mail, or Smartphone, the
production status (among others – figure
plant manager will be alerted of problems,
complete with the context in which they occurred. This will allow him to analyse the
into the enterprise
Any anomaly or alarm condition will
situation with all the real-time facts at his
cause the appropriate icon to flash red
fingertips before taking action. This action
whereupon he can click on it to see more
will most probably involve communication
details and drill down to the cause of the
with other personnel and, since this is part
event and how it is being handled.
of the process flow for this activity, it will be logged by the Workflow software in much
The production manager
the same way as a SCADA system logs its instructions and the response to them.
He may well be out and about visiting suppliers and customers. His only
contact with the office is his cell phone (or any of the currently available mobile
The important thing about operators is that
Figure 5: Whatever else he may be doing, the system
devices – i.e. Smartphone, iPhone, iPad,
they have to react to a single version of the
engineer can be informed of KPIs of his choosing
etc.) but he might want to assess the
truth and they have to so in real-time. They
6 | www.protocolmag.co.za
What amounts to “right information”?
will invariably be at the plant and can receive communications by way of e-mail, phone, Smartphone, radio or their own HMI / SCADA screens. Many operators will wander from station to station yet they need to be alerted of all events and alarms wherever they might be. Response to an event will require guidance if that event has occurred before and their solution and response recorded for the future. Operators are most likely to be swamped with data such as an avalanche of alarms and that’s why information screening and prioritisation is most important in their case. One thing needs to be quite clear: If operators are to execute instructions from higher up, those instructions must be based on the same information available to both camps. Hopefully, the decision will not only Figure 7: The plant manager can trace task progress with the help of ArchestrA Workflow software
be based on the available facts but also on the experience and knowledge of the decision-maker.
Conclusion Unless it’s the right information, as per the definition in this article, it’s likely to be more of a hindrance than a help. Any one TV advert, for example, will only appeal to a narrow segment of the watching audience and will be tuned out by the rest as “noise”. Similarly for the “wrong” information supplied to the individuals in an enterprise who all share a common reality but are each interested in a different aspect of that reality. Something else which is apparent from the above is the fact that information collection and delivery is based on a five-dimensional matrix of possibilities (who, what, where, Figure 8: Operators often need access to more than process control information
when and how). So it’s no longer good enough for an application to get data, process it in its own way and output the result for “whoever”. Today, an application must be able to source data from a variety of sources (including other applications), process it in the way the end-user needs and communicate the information through a growing number of media from printers to Smartphones. If all the applications an enterprise needs are built with all this in mind and can cooperate with one another, then so much the better – especially if they all come from the same stable.
May/June 2012 | 7
Selective Retrieval and Information Collation The data retrieved will depend on the application, which will initially
not to say that the data werenâ€™t informative in their own right but that
probably use that in its own database. Thereafter, these applications
they are now aligned and collated in such a way as to be meaningful to
may need other data which will have to be retrieved selectively
a variety of personnel who each have different jobs, goals and priorities.
from other databases and collated in such a way as to provide the information necessary for various reports.
The collation of context-rich information from various sources and applications is the key to less guesswork as well as maximised
These are important steps in the information process where isolated bits of data become context-rich information for the first time. This is
8 | www.protocolmag.co.za
knowledge and decision support at all levels
Information Collation: Wonderware Intelligence
Information Collation: Wonderware Intelligence
Wonderware Intelligence’s plant model is easy to create, using the
In a nutshell ...
Wonderware Intelligence is the industry’s first
Wonderware System Platform development
EMI (Enterprise Manufacturing Intelligence)
environment to model both historical
Wonderware Intelligence is a tool that allows
product that leverages the Wonderware
and transactional data as well as to set
you to access, aggregate, contextualise
suite of Reporting and Analysis products.
up the relationships and the information
(provide relationships) and visualise your
Built on top of Wonderware System
plant data, whether it is from Wonderware or
Platform, Wonderware Intelligence creates
Create metrics that make sense for your business
database or SAP ERP data) and to
Wonderware Intelligence creates
• Visualisation through an easy-to-configure
format, store and present that data in
personalised Key Performance Indicators,
an intuitive dashboard, allowing you to
allowing you to view the metrics that
make immediate decisions on your plant’s
are important to you to determine plant
performance. Data is updated according to
performance or adherence to operating
your needs, to provide you with a current
goals. Use Wonderware Intelligence to
view of plant asset utilisation; product quality
determine uptime over plants, by specific
and yields, throughput, or labour, resource
lines, shifts and personnel. Look at quality
Indicators to mirror your information
and energy consumption.
plant by plant. Perform ad-hoc analysis of
an information framework to take both Wonderware and non-Wonderware data sources (such as an OSIsoft PI Server
dashboard • Data structure through a comprehensive Information Model • Ability to create Key Performance
• Ability to collaborate and share metrics through a web-based dashboard
any data that is stored in any of your plant applications, whether it’s in a historian, MES, LIMS or SAP ERP system. These analyses are published in a dashboard format, using the Intelligence Analytics Client, allowing you to share your findings over the web for greater collaboration.
May/June 2012 | 9
Intelligence server The Intelligence Server provides core Intelligence functionality, with its contextualisation of data sources into an Information Model. The Intelligence Server is scalable, from a single site/single server to multiple servers for hosting data from multiple sites. The Intelligence Server can aggregate data from other servers, and compare data across sites. You can establish a hierarchical data structure for aggregating multiple databases into one data store.
Intelligence clients Wonderware Intelligence Standard Client Intelligence Standard Clients provide viewing access to published Dashboards, and allow the user to browse and navigate
dashboard reports to determine cause and
the Intelligence content. The Standard
Clients employ “one click” technology for
Wonderware Intelligence has been designed so that the process or plant engineer can quickly develop and publish to the web their
ease of use in deployment.
For any industry and any type of data
own dashboard views of KPI’s, using existing
Wonderware Intelligence Analytics Client
data from your plant, quality, and enterprise
Wonderware Intelligence is a tool that can
applications. This not only saves valuable
be used in any industry—whether you are in
Intelligence Analytics Clients enable a user
IT resource time and costs, but provides a
food & beverage, primary metals, chemical,
to analyse data, and create and publish
collaboration framework for you to further
oil and gas or energy. It accesses the data
rich, intuitive Dashboards that feature
leverage the investments you have in these
you need to manage your business, whether
drill-down capabilities for root-cause
solutions, not replacing, but supplementing
that data comes from your Wonderware
analysis. The Analytics Clients can configure
with an overlay for more transparency to
system, ERP, LIMS or other enterprise or
reports and dashboards that encompass
existing Wonderware Reporting Content
Works with your products
Unlock the data in your existing applications,
Wonderware Intelligence is a natural
and share it company-wide! Wonderware
extension to Wonderware’s full-featured
Intelligence provides a framework for easy
reporting and analysis product portfolio.
Wonderware Intelligence Server supports
data access and visualisation, comparing
There are three components of the
Windows XP, SP3 (single node, 32 bit);
important metrics such as quality by shift,
Wonderware Intelligence product:
Windows 2003 SP2 (32 bit only); Windows
from Information Server, Active Factory, or
yields by line, or other parameters that are key to your performance.
2003 R2 SP2 (32 bit only); Vista SP2 Ultimate • Server, creating the information model and doing persistent data storage
Intelligence can be used with Wonderware products, including InBatch, InTouch,
(both 32-and 64-bit, single node); Vista SP2 Business (both 32-and 64-bit, single node); Windows 2008 Server SP2 - Standard and
• Standard Client, for viewing web-
Enterprise (both 32-and 64-bit); Windows
Wonderware MES (Operations and
based dashboards, as well as reports
2008 Server R2 SP2 - Standard and
Performance) and Energy Management
from Wonderware ActiveFactory or
Enterprise (both 32-and 64-bit); Windows
for a single view of your plant wide
Wonderware Information Server
7 Professional (both 32- and 64-bit, single node) and Windows 7 Ultimate (both 32- and
process data. Utilise existing Wonderware Reporting Products—HMI Reports,
• Analytics Client, creating and publishing
64-bit, single node).
ActiveFactory, ArchestrA Reports and
dashboards that provide real-time
Wonderware Information Server by viewing
analytical capabilities on Intelligence-
Wonderware Intelligence Server supports
this source data when drilling down into
Microsoft SQL Server 2008 with SP1: Express,
10 | www.protocolmag.co.za
Information Collation: Wonderware Intelligence
Standard, and Enterprise editions, 32-bit and 64-bit versions. Wonderware Intelligence Clients support Windows XP, SP3 (32- bit); Windows 2003 SP2 (32 bit only); Windows 2003 R2 SP2 (32 bit only); Vista SP2 Ultimate (both 32- and 64-bit); Vista SP2 Business (both 32- and 64-bit); Windows 2008 Server SP2 - Standard and Enterprise (both 32- and 64-bit); Windows 2008 Server R2 SP2 - Standard and Enterprise (both 32- and 64-bit); Windows 7 Professional (both 32- and 64-bit) and Windows 7 Ultimate (both 32- and 64-bit).
Look to Wonderware to make EMI as easy as HMI Wonderware Intelligence is the latest in the
Wonderware Intelligence was chosen as the Best Dashboard of 2010 by the readers of Control Engineering magazine.
family of operations management solutions from Invensys, providing you with software to help you get more out of your existing assets and resources. We unlock the value of your existing data to make Enterprise Manufacturing Intelligence easy, scalable and with fast time-to-benefits.
May/June 2012 | 11
Information Collation: Wonderware QI Analyst
Improve product quality and accelerate margins
Manage product quality to increase plant performance
Manufacturing high-quality products
Wonderware’s QI Analyst software gives
at a competitive price requires a
manufacturers the ability to monitor process
team effort. Wonderware’s QI Analyst
variation in real time — an important
software provides a versatile tool for
indicator of product quality. Using powerful
collaborative decision making. QI Analyst
SPC analysis techniques, operators and
software connects your entire quality team
plant decision-makers can make immediate
with near real-time Statistical Process
online adjustments to proactively ensure
Control (SPC) information, enabling
production quality and consistency.
everyone to proactively reduce excessive
Get your first line of defence into the game
process variations —instead of reacting to
The software gives your production team
them after a problem occurs. In fact, with
the quality information and notifications it
Operators are a plant’s first line of
real-time SPC data, QI Analyst software can
needs to adjust process parameters on the
defence when if comes to product quality.
help you “predict” problems, before they
fly — lowering costs and improving product
However, operators demand software
cost you time and money!
quality. Contrast with traditional off-line SPC
solutions that do not adversely affect their
systems—they use historical process data
activities. QI Analyst 8.0 software can be
and don’t allow real-time corrections of
easily configured to provide the real-time
SPC information operators need to visualise and “steer” real-time product quality. SPC
12 | www.protocolmag.co.za
In addition, QI Analyst software can leverage
information can be tailored to each user’s
historical data from most data sources within
individualised needs, so there is less to learn
the plant, empowering manufacturers
and less resistance when implementing a
to transform common process data into
real-time SPC system. The bottom line is that
actionable process information. The software
QI Analyst 8.0 software can give operators
can quickly analyse data, plot variations and
the quality information they need in real
provide information about the performance
time, to positively affect product quality and
of your critical plant processes.
Information Collation: Wonderware QI Analyst
Make consistent, real-time decisions organisation-wide
Users across the globe rave about the QI Analyst software’s ease of configuration
In a nutshell ...
and use. You don’t need to be an expert Wonderware’s QI Analyst software
in statistics to use the product. Set up
Useful in nearly any vertical industry,
offers a rich selection of communication
functional charts in minutes. The new
Wonderware QI Analyst Statistical Process
options, giving each member of your
Products/Parts feature empowers you
Control (SPC) software is an important part
team immediate access to the same
to configure charts for hundreds of your
of any quality management programme.
information — for consistent decision-
products quickly and efficiently. Help is
making throughout the organisation.
always just a click away, with an online
Performing both on-line and historical
Customisable alarms can immediately alert
tutorial and glossary to accelerate results.
SPC, QI Analyst supports real-time process
key plant personnel regarding important
monitoring and alarms as well as historical
quality issues (e.g., by sending dynamic
reports to view process “health” over any
messages to a pager).
period of time. Real-time SPC, analysis and reporting are equally easy.
View SPC charts from anywhere in the plant
By storing process data in the QI Analyst database and linking to external data
QI Analyst’s ChartService, a Microsoft
sources, users can leverage enterprise-wide
Windows service, automatically monitors
SPC to reduce variation, reduce costs of
your process data and reports on alarm
manufacturing and increase productivity.
status via a new alarm dashboard. This
control can be embedded in an HMI, like Wonderware’s InTouch HMI or a customised industrial application to
QI Analyst software can help you “predict”
automatically communicate SPC alarm
problems, before they cost you time and
status. It can accommodate a large number
money! The results — improved product
of critical process parameters and send
quality, increased productivity and reduced
information to a wide range of plant
costs — can be dramatic. And they all can
lead to higher profits!
A comprehensive selection of SPC charts and powerful statistical tools
• Real-time data charting, calculations and alarms
alarm dashboard control can be configured
QI Analyst software automatically tests real-
• Quick operator reaction to process problems
to meet each user’s unique information
time process data against statistical rules to
detect trends, runs, patterns and outliers.
Operators and plant decision-makers can keep tabs on key process parameters, enabling them to proactively manage
product quality and plant performance. The
• Predict problems that are about to happen
When a rule violation occurs, QI Analyst
You don’t have to be a statistics expert to use QI analyst software
software immediately charts the point in red. In addition, customisable alarms alert you
• Report the “health” of manufacturing processes
whenever key data goes out of specification; so you can start solving quality problems
Wonderware’s QI Analyst 8.0 software was
immediately. For example, if a rule violation
created with ease of use as a primary goal,
occurs, the software can call your pager or
resulting in a product that is intuitive and is
send you an email. QI Analyst software is
very easy to configure and use. Based on
also integrated with Wonderware’s InTouch
the Microsoft Windows operating system,
HMI and the Industrial Application Server’s
QI Analyst software usually offers more than
alarm management features. So, if an SPC
one way to accomplish the same task —
rule is violated, QI Analyst software can
minimising training time.
serve alarm information to these important
Key capabilities • Full complement of SPC charts • Real-time and historical SPC • Link to virtually any existing data source • Database backbone
plant information systems. • Enterprise SPC, accommodating many You’re never more than a glance or an
users at once
alarm away from critical information. A large library of statistics can be displayed
• 21 CFR Part 11 compliant
for the overall process, or for any individual process parameter — aiding in continuous improvement efforts. Limit
• Integrated to InTouch HMI, Historian and System Platform
May/June 2012 | 13
sets allow for the easy comparison of two
sets of data, accelerating process analysis efforts. Lastly, save charts and workspaces as
including Western Electric, AIAG, Juran, Hughes, and Gitlow & Duncan. These rule
HTML files for easy posting within web-
sets automatically detect process excursions for a host of different industries. QI Analyst
All standard SPC charts are included in QI
• Defects Per Million Opportunities (DPMO)
software also facilitates the modification of supplied rule sets — or you can design your
own rule sets to achieve the most precise statistical analysis of your unique processes.
Special Charts and Analysis Tools • Variable Charts • Run • X-bar and Range or Sigma
Put your product quality and process capabilities in context
• Histogram (view the data distribution) • X-individual and Moving Range
The tighter integration of QI Analyst 8.0 • Scatter plot (view the correlation between
• Moving Average and Range or Sigma
software with Wonderware’s InTouch HMI, Wonderware Historian and the state-of-theart ArchestrA System Platform enhances your
• Cumulative Summation of Means or Individuals
• Paretos of nonconformities, causes, actions or rule violations
system visualisation capabilities. QI Analyst software can also relate production and process-quality information to traceability,
• EWMA of Means or Individuals
Tailor statistical rule sets to fit your unique application
Attribute Charts: • p
14 | www.protocolmag.co.za
equipment performance and overall manufacturing success. This integration of production information enables improved
A number of industry-specific rule sets
documentation and improved production
are delivered with QI Analyst software,
processes. So, in essence, QI Analyst
Information Collation: Wonderware QI Analyst
8.0 software facilitates improvements in operational excellence and brand integrity,
Integrate QI analyst software with your IT system
Achieve enterprise-level scalability with one, consistent SPC solution
Using the QI Analyst Workstation, plant floor operators can watch the various
and fosters an integrated approach to production and performance management.
• Plant-floor operators
You can integrate the software with your IT
process charts, enter data — manually
system using centralised setup and security
if not already automatically collected
features, with the extra benefit of flexibility
via direct communication links — and
for system customisation.
receive alarm notification if any of the charts they are monitoring violate
Wonderware’s QI Analyst software is
statistical rules. User workspaces can be
QI Analyst’s architecture can integrate with
designed for organisations with large
set up for each operator so that, upon
your current IT set up, enabling enterprise-
and varied data sets, a complex IT
login, the software automatically pulls up
level scalability. As a result, all of your plants
structure and a need for flexible system
that operator’s charts, re-establishes data
can use the same SPC solution, minimising
links, and begins charting and alarming.
long-term ownership costs. The distributed architecture of Version 8.0 can place
Alarm dashboards linked to the new
FDA 21 CFR part 11 ready
real-time information at the fingertips of
to enable quick verifications of SPC alarm
every person in your organisation — without
Product quality is a key manufacturing
disrupting your current IT infrastructure.
concern in today’s regulated industries, such as the pharmaceutical and food and
Power users and system operators can access SPC information
Alarm Status Service can be configured status via red-light/ green-light displays. • Quality personnel
beverage industries. Regulated industries
The QI Analyst Workstation enables
have special recordkeeping requirements
quality personnel to take measurements,
that must be built into a SPC tool to allow
enter data automatically through their
for validating SPC applications. QI Analyst
gages, or enter data manually to verify
The QI Analyst Controller assists power users
8.0 software provides audit trails for changes
that the variables or attributes entered
to create a broad range of SPC charts, and
in parameters, alarms and data. Version 8.0
yield a process that is stable and in
to perform many types of statistical analysis.
also supports Windows Integrated Security,
control. Custom SPC reports using
The Controller also enables setup and
making QI Analyst 8.0 software a good fit for
Microsoft Excel spreadsheet software or
maintenance capabilities. The QI Analyst
your plant’s existing user security model.
Word can be created and distributed to
Workstation helps less technical users like
system operators get access to real-time
That’s why Wonderware’s QI Analyst 8.0
SPC charts and alarms, enabling them to
software is FDA 21 CFR Part 11 ready. It
act on process issues before they get out of
simplifies and lowers the costs of creating
Using QI Analyst Controller, IT managers can
SPC systems in regulated industries such as
use QI Analyst software to manage all user
pharmaceutical, food and beverage, power-
accounts. The manager can set rights, define
generation and others.
log-on profiles, and maintain the QI Analyst
Connect to legacy data sources Virtually any open process database that’s accessible on your plant or enterprise
• IT managers
network through a few intuitive, easy-to-use
A variety of plant personnel can benefit from QI analyst software
network can be used as a data source by QI
dialog boxes. The flexible security model is also easy-to-use. Also, because all the administrative data is maintained in one database, one person should be able to
Analyst software. As a result, the majority
QI Analyst 8.0 software is designed to
easily manage the QI Analyst network,
of your plant’s legacy plant sources can be
enhance today’s most powerful enterprise-
regardless of how large it gets.
tapped for valuable SPC monitoring and
wide manufacturing systems, benefitting a
analysis. Plant performance monitoring
wide range of functional groups.
efforts can therefore be increased — driving greater awareness of real-time product quality and plant performance.
Use QI analyst software throughout multinational manufacturing enterprises
• Corporate personnel Corporate personnel can use QI Analyst
• Quality managers
charts, alarms and tables to analyse
Using the QI Analyst Controller, Quality
real-time SPC information when making
Managers can set up data tables (logical
decisions about valuable plant assets and
groupings of variables and/or attributes
how to increase profitably.
to be collected and analysed), charts, statistical rules, and alarms to maintain
QI Analyst product highlights
real-time control of online manufacturing QI Analyst software has been localised in
processes. They can also analyse “old”
many major languages so that applications
process data off-line, manipulating limits
can be used throughout modern multi-
and probing the data for useful process
national manufacturing enterprises.
• Complete range of real-time and historical SPC charts and alarms • Broad connectivity to plant data sources
May/June 2012 | 15
• Integration to ArchestrA Industrial
QI Analyst 8.0 consists of:
Application Server data sources
• Microsoft Windows 2008 R2 with Service Pack 1 (x86 & 64 bit);
• QI Analyst 8.0 Controller — A full• Enhanced access to data in the InTouch HMI and Wonderware Historian
featured desktop application enables all basic SPC activities (data entry, charting,
• Microsoft Windows 7 with Service Pack 1 (x86 & 64 bit);
statistical calculations, rule evaluations • Rapid system and chart configuration
and alarming), as well as complete set up, configuration and administration
• User-configurable SPC rules
Service Pack 3;
capabilities. The Controllers are recommended for Power Users, Quality
• Versatile ActiveX SPC chart control for
• Microsoft Windows XP Professional with
Engineers and Administrators. The
• Microsoft Windows Server 2003 with Service Pack 2.
integration into the InTouch HMI, Internet
Controller can run on a specific device
Explorer browser and other applications
(PC) on a concurrent basis or on a
Database Requirements (for QI Analyst
Terminal Services Server.
Admin and Process Databases): Access 2000
• Powerful background monitoring of process data and alarms • ActiveX alarm status and dashboard control
and 2003 (for single node systems) SQL • QI Analyst 8.0 Workstation — Typically
Enterprise, and R2 editions); Oracle 9, 10,
enables basic SPC activities like data
and 11G R2.
entry, charting, statistical calculations, rule evaluations and alarming.
• Rapid set up support for large numbers of products and parts
The Workstation can run on a specific device (PC), on a concurrent basis or on a Terminal Services Server.
• Multi-lingual support
Operating Systems • FDA 21 CFR Part 11 ready • Microsoft® Windows® 2008 Server with • Powerful system administration functionality
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Server 2005 and 2008 (Express, Standard,
used on the plant floor, the Workstation
Service Pack 2;
Information Collation: Wonderware Historian Client (previously ActiveFactory)
Information Collation: Wonderware Historian Client (previously ActiveFactory)
Make intelligent plant decisions in real time with Wonderware Historian Client
viewed, analysed, consumed and reported in various industry standard software such as desktop applications, web browsers and external applications, such as Microsoft Office, Wonderware’s InTouch® HMI or
Wonderware Historian Client delivers production and performance ®
even custom clients.
information quickly and easily in visually informative formats enabling operations, engineering, quality, and management to make critical real
Data analysis and reporting
time decisions improving productivity, rapidly adapting to change, and optimising production and performance of the operation.
The rich, desktop-based analysis and reporting experience gives engineers ad hoc query capabilities and preconfigured trending
A versatile client architecture
tools needed to drill down into data details and evaluate trends, find problem root causes and determine the best solutions.
Wonderware Historian Client is versatile and open so data can be Wonderware Historian Client includes multiple applications designed to maximise the value of data stored in Wonderware Historian. These applications give you access to plant and process data through easy to use interfaces. Using information from these powerful tools, p lant workers can quickly troubleshoot problems, study potential operational inefficiencies and eliminate the time-consuming process of locating data.
Trend Client The Wonderware Historian Trend client is a powerful desktop data graphing tool. Providing a range of charting and formatting capabilities, it is designed to allow users to create highlyinformative data analysis charts for real-time and historical data trend analysis, faster troubleshooting and process improvement.
May/June 2012 | 17
In a nutshell ... Wonderware Historian Clients (previously known as ActiveFactory) provide rich data analysis and reporting capabilities to maximise the value of your information stored in the Wonderware Historian. Wonderware Historian Clients are integrated with Microsoft Office components to deliver data-trend and numerical data analysis using Microsoft Excel, comprehensive data reporting using Microsoft Word, and the capability to publish real-time and historical plant information to the Web or company intranet site using Wonderware Information Server. Plant knowledge workers using information derived from the Wonderware Historian can quickly troubleshoot problems, study potential process inefficiencies and eliminate the time-consuming process of locating the data. Wonderware Historian Clients make the
Multiple types of analysis displays and reports are available as standard,
delivery and visualisation of this information easy to implement and
deploy. • Trend charts
Business value • X-Y Scatter plots Wonderware data analysis and reporting clients deliver information from the primary information flows found in any manufacturing
• Batch trend charts, including ‘Golden Batch’ comparison
or industrial operations environment: Production Management information from your business systems to the plant floor and
Performance Management information from your assets and activities to your business systems.
This add-on for Microsoft Word® enables users to create custom production reports using Wonderware Historian data and save/
publish in standard document formats. The Report client can use the Wonderware Historian Query client to allow the creation of highly
• Improve plant productivity, agility and performance
focused reports tailored to specific user requirements.
• Proactively identify process inefficiencies and simplify plant performance
reporting • Produce on demand and scheduled reports for regulatory compliance and management • Publish reports easily to intranet or Internet servers
Key capabilities • Real-time and historical data trends and reports • Integrate diverse HMI and ArchestrA namespaces within a single interface • Simplified data queries which understand your process and information needs • Integration with and support for Microsoft Office® via Excel® and Word® add-ins
This Microsoft Excel add-on is designed to simplify the creation of process-data reports using Wonderware Historian data. Wonderware Historian Workbook reports can be published to the
• Integration with Wonderware System Platform components including Wonderware Historian and Wonderware Information Server
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Wonderware Information Server portal for broad distribution across the plant, intranet or Internet.
Information Collation: Wonderware Historian Client (previously ActiveFactory)
Query Client This easy-to-use desktop tool for creating database queries removes the need for SQL expertise. Query can be used in tandem with the Wonderware Historian Trend, Workbook or Report clients. It can also be used as a standalone querying tool for the Wonderware Historian or any SQL-compliant database.
Web Reporting Wonderware Historian Trends, Reports and Workbooks can be published via a simple menu selection to the Wonderware Information Server. Using Wonderware Information Server aggregates plant and business data into a powerful Web-based production and performance management solution.
Extensibility To enable seamless integration within your enterprise applications, the Wonderware Historian Clients also have componentised objects which enable you to integrate the powerful analytical and visual capabilities of the suite within your own applications. Wonderware Historian Client is built on ArchestrA® technology, which allows unprecedented scalability and functional richness in industrial applications. Using ArchestrA technology, manufacturers can build complete production and performance management solutions using the single, integrated development platform that ArchestrA delivers — saving time and development resources. Applications can start small and grow into a complete plant-wide or enterprise solution as requirements dictate or evolve.
Client Control Objects In addition, valuable process and operations data can be used Invensys provides a powerful library of component-based .NET and
t o annotate your process data. This contextual information is
ActiveX control versions of the Wonderware Historian Client, enabling
invaluable for understanding process performance and becomes part
extensibility options for customers wanting to build custom industrial
of your plant’s data record — making future optimisation and
applications. These client components also are able to be used
troubleshooting activities more efficient and effective. Annotation
with Wonderware’s flagship HMI, InTouch, and third-party container
automatically captures the user name and the time and date of the
applications, such as Microsoft’s Internet Explorer and the Visual Studio
Powerful data retrieval modes Toolkits Plant IT personnel tasked with creating and maintaining production Wonderware Historian Client control objects are developed using .NET
reports and regulatory reports can streamline data queries needed
and C# software technology, enabling them to be seamlessly integrated
to pull important information out of the huge volume of plant
into today’s .NET-based custom industrial applications. Should you
process data stored in Wonderware Historian. Users can add new
further wish to integrate elements within custom applications, a range
content to existing production reports or create new production reports
of toolkit options are available to save you significant development
that were difficult or impossible to create in the past.
Easy real-time data mining Using the Query client enables you to easily and rapidly mine data
Easily access summary information about all displayed tags, including
stored in Historian and other SQL data sources. No prior knowledge
minimum and maximum values, the times associated with those
of SQL is required since a simple tag browser is used to find and
values, average values, ranges, etc. Summary statistics can be
select individual tags or entire public or private tag groups. Query
calculated for the entire trend interval or for only the period between
provides a wide range of standard query types and also allows users to
time cursors. Summary statistics data can be saved or printed.
save favourite queries.
May/June 2012 | 19
client components within Wonderware’s Information Server delivers a rich and flexible portal experience. Sample reporting solutions include: • Table Weaver - dynamic, drill-through reports and data displays • Wonderware Performance - OEE and equipment downtime reports and KPI dashboards • Wonderware Operations – multiple reporting options including: Production events and formula reporting (usage and set-points) Material consumption including comparisons of “plan vs. actual” Consumption and genealogy of materials, equipment, personnel
Wonderware information server Reports from other Wonderware software solutions can be integrated with those created by Historian Client and made available over the Web using Wonderware Information Server. This ensures the proper information formatted appropriately can be made available to the right individuals wherever they are located. Using
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and production events related to a lot, batch or serial number Complete traceability and genealogy reporting to help you comply with government regulations
Information collation and contextualisation
Information collation and contextualisation This is where context is married to data and everything becomes information for the first time. The right bits of data are coaxed from their respective databases, synchronised with a time stamp and shipped off for dissemination. But, until comparatively quite recently, this was a very difficult exercise. Locked and proprietary databases as well as the lack of data exchange standards accompanied by company politics and security concerns precluded the collation of information from many valuable contextual sources. Solutions like Wonderware Intelligence have overcome these barriers and today provide layered, contextualised information at many levels with what has become known as Enterprise Manufacturing Intelligence or EMI. In fact, the value of EMI and Business Intelligence (BI) lies in the context they provide â€“ otherwise they would simply be reporting tools
May/June 2012 | 21
Information Dissemination In a way, the information process can be regarded as a karaoke system:
You may have the finest Hi-Fi components in the world but if the
The microphone picks up the singer’s voice (data collection), merges
speakers aren’t working, how could you tell? The dissemination aspect
it with a pre-recorded soundtrack (contextualisation) and outputs the
of the information process has to be able to communicate the result of
all the hard work that’s gone into aggregating the required knowledge for informed decision support otherwise it’s all been for nothing.
But the karaoke system has an easy job: It only has one audience and one message. Real-life information systems have a much more
Thankfully, today we have hardware and software technologies well up
demanding task. They have to cater for a wide variety of audience
to the task.
interests and they must be able to deliver the required information through an increasing number of communication channels – and they must do it in real-time.
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Information Dissemination: Wonderware Information Server
Information Dissemination: Wonderware Information Server
Key production/process information anywhere
Wonderware Information Server Web Clients are designed for the more casual user who relies on a Web browser to access real-
Wonderware Information Server provides the full spectrum of industrial
time dashboards, pre-designed reports of industrial activities as
information content including process graphics, trends and reports
well as the occasional requirement for ad-hoc analysis or write back
on a single web page. It acts as a unified web server source for all
capabilities to the process.
System Platform, InFusion, Historian, Intelligence, Batch, and MES online client and reporting capabilities. This enables employees across the enterprise to make better-informed decisions based on the real-
Easy access to information enables productivity and cost improvements
time status information and historical data they need to improve operations. Wonderware Information Server software also helps connect
Keeping costs to a minimum is vital in today’s competitive marketplace.
personnel with non- Wonderware data sources so they can access overall
One important way to reduce costs is through the optimisation of
perfo rmance records using a single source of information.
production processes. To do this effectively requires accurate process data and a way to easily expose it to key operators, engineers and managers. Through better understanding of production processes, workers can improve their operations intelligence and the ability to improve performance. Data Analysis and Reporting Software from Wonderware can deliver production and performance information. Wonderware Information Server easily distributes this information to all groups within your organisation such as operations, maintenance, engineering, planning, quality, purchasing and receiving. These analysis and reporting software solutions are ideal for delivering decision making information to groups tasked with plant-wide initiatives such as asset management, lean manufacturing, Six Sigma or other productivity improvement programmes.
May/June 2012 | 23
In a nutshell ... Wonderware Information Server is an easy-to-implement solution for aggregating and presenting plant production and performance data over the web or company intranet. Operations, facilities management and engineering personnel have a direct view into critical processes, enabling better collaboration and troubleshooting. Plant personnel, with a minimum of training, can install, configure and implement a highly effective plant information portal without the need for custom web programming. Real-time visualisation of the production process can be viewed anywhere – via the Web or company intranet. Information Server aggregates a wide range of operations and performance information, including process trends, KPI (Key Performance Indicator) dashboards, production reports, equipment downtime, equipment efficiency, operations events and history, including product
Enable process improvement collaboration
traceability and genealogy information. To be most effective, managers need to engage the entire workforce Content from the Wonderware Information Server can be incorporated
in process improvement initiatives. Information is key to unlocking
into other web portals, making existing corporate IT portals more
the creative talents of workers. Armed with up-to-date and accurate
informative and valuable.
performance information, workers can solve process issues faster and discover hidden opportunities. Wonderware Information Server
software is the essential tool needed to deliver this vital information to the entire enterprise cost effectively.
Wonderware Information Server software enables workforce collaboration across the enterprise based on accurate, real-time information, anytime,
This Wond erware web-based solution aggregates a wide range
anywhere, to solve process issues faster and discover hidden opportunities.
of operations performance information including process trends,
Wonderware Information Server minimizes the cost of publishing operations
Wonderware Intelligence dashboards, production reports, equipment
reports and web clients into your company network, by an IT friendly web
downtime, equipment efficiency, operations events and history,
server concept and configuration tools out of the box.
including product traceability and genealogy information. This can help reduce the time spent in department meetings because everyone has
access to complete and accurate process information and the reasons for production losses. Wonderware Information Server software enables
• Easy to implement web information portal
each worker to view just the information they need via personalised Web content — even in multiple languages.
• Access to Key Performance Indicators (KPI) anywhere, at any time • Keeps everyone better informed on plant performance
Reduce total cost of ownership with a solution designed for operators, engineers, operations managers and IT
• Accelerates troubleshooting and decision making Wonderware Information Server software helps significantly reduce the • Facilitates productivity and workforce improvements
need to have IT staff design, implement and maintain web applications. Wonderware Information Server is easy to install. While it provides all
capabilities ready to start out of the box, typically IT will support the
• Real-time and historical plant data
compliance with corporate policies. Wonderware Information Server is
setup by providing the server and security infrastructure to ensure built on top of industry-standard Microsoft technology and security, and • Online access to plant process graphics
embeds smoothly and compatibly in corporate IT system landscapes. Once established, plant personnel, with a minimum of training, can
• Integrated data trending and analysis
configure and implement a highly effective plant information web site without the need for custom web programming. Layout and content
• Production and performance reporting
management are designed to be performed by Operations, leveraging their process and production know-how to share the information
• Integration with existing IT infrastructure and web portals
which really impacts operational efficiency. It helps reduce the burden on plant IT personnel by lowering the technical barriers for creating
• “Container” for Wonderware Intelligence reports
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and maintaining an operations information website, enabling users to
Information Dissemination: Wonderware Information Server
• Real-time and historical information from supervisory systems via charts, trends, data tables and graphical displays from the Wonderware System Platform, Invensys InFusion ECS and InTouch HMI software. • Rich Data Analysis is provided with Wonderware Historian Client capabilities, including feature-rich trend charts and X-Y scatter plots. • Reporting content is out of the box, included with Wonderware MES and Wonderware InBatch software; flexible and extensible, based on Microsoft SQL Server Reporting Services. • EMI dashboards and drill-down analysis can be provided by Wonderware Intelligence Software. • Any database or historian that supports A DO/ODBC connections can be displayed in universal charts or data tables. perform ad hoc analysis and reporting using their Microsoft® Office® skills to dramatically increase visibility into actual operations and processes.
• Third-party systems via open interfaces such as HTTP or content available as HTML reports, designed to be displayed over a browser,
Add operations information context to corporate portals
can be incorporated into Wonderware Information Server.
Process graphics anywhere
Content from the Wonderware Information Server can be incorporated into other web portals, making existing corporate
Real-time visualisation of the operations process can be viewed
IT portals more informative and valuable. Knowledge about the
anywhere – via the Web or company intranet. Operations, facilities
actual status of production, performance or cost impact can
management and engineering personnel can have a direct view into
improve production planning to be more profitable. Operations
critical processes, enabling better collaboration and troubleshooting.
management and supervisors do not need to consult several sources of
InTouch HMI process graphics as well as ArchestrA Graphics used in
information if they are required to bring the business information
Wonderware System Platform and Invensys InFusion can be easily
in context with operational information. Wonderware Information
published into the Wonderware Information Server software, and
Server content is ready to be integrated with any system, based on
viewed in a browser acting as an Information Server Web Client.
Microsoft SharePoint technology, to enable a single enterprise- wide
Process adjustments can be accomplished remotely using the
Wonderware Information Server’s optional write-back functionality. Wonderware Information Server 2012 leverages Microsoft Silverlight
Wonderware information server features
technology to provide high performance and functionally rich information displays within a web-oriented solution.
Wonderware Information Server software helps deliver accurate, timely data in a very cost-effective manner, enabling personnel to be better
Secure and easy-to-implement web solution
informed on operations. Wonderware Information Server software can facilitate access to a broad range of real-time data sources, including:
To keep operations information safe and secure, Wonderware Information Server software is delivered with built-in safeguards to
May/June 2012 | 25
protect information from unauthorised access, and prevent users
without privileges from performing certain functions. Security features include:
Personnel can use Wonderware Information Server software to access the broad range of operations information delivered
• Integrated Microsoft Windows® operating system authentication
by the Wonderware Information Server software Web Content Server. Client access is possible from any Web-enabled PC. In
• Encryption/security - Secure Sockets Layer (SSL), Digital Certificates and Single Sign-On protections
this way, personnel can participate in process improvements and troubleshooting, even when they are away from the facility.
• Firewall-friendly - The portal can be placed inside a DMZ
• Portal roles - The portal administrator assigns Read, Write and
• Microsoft SharePoint Services
Administration privileges • Microsoft SQL Server Reporting Services Intelligent Content Linking • Publishing rights - Users must be assigned remote and local publishing privileges
• Wonderware Table Weaver, which provides streamlined content linking & powerful drill-through capabilities
Wonderware information server 2012 software consists of:
• Alternative data displays for richer data visualisation
Web Content Server
The Web Content Server provides a software infrastructure for
• Bar charts
building operations information website content by publishing information views, dashboards and reports from other Wonderware or
• InTouch SmartSymbol displays
Invensys Operations Management software applications, or it can use graphs and tables with a database query. The generated information content can be used within the included Portal for navigation and administration, or via web parts or links inside exiting portal infrastructures customised to your company’s requirements. Userspecific views can be tailored to particular work responsibilities.
Web Server framework • Home Page • Portal personalisation • Centralised administration & management • Integrated Security • Extensive Search • Multi-language Support
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• ArchestrA graphics
May/June 2012 | 27
Information Dissemination: Wonderware HMI Reports
Easily create reports from information in Wonderware InTouch HMI and other data sources A common problem
Simple, smart, secure
Take control of your data
Wonderware HMI Reports is the most
• Quickly and easily consolidate your
intuitive and easy-to-use reporting
InTouch HMI or Historian data into
solution available on the market
concise visually appealing reports to
today. It is specially designed for
better understand your processes and
industrial automation. Wonderware
Accurate and visually-appealing reports can
HMI Reports doesn’t require any IT or
be difficult to create, take time to configure,
programming skills. Configuration is
and typically require work from the IT
done through simple interfaces, menus,
department or an outside resource at added
intelligent report objects, and
cost. Even minor changes can take days.
friendly dialog boxes. Wonderware HMI
• Create reports up to ten times faster than Crystal Reports or Excel • Generate and distribute custom Reports
Reports significantly reduces Report
automatically in Excel, Adobe Acrobat
Wonderware HMI reports is the solution
development time and simplifies Report
format (PDF), email and HTML formats
Wonderware HMI Reports significantly
Make reports available to any authorised
fast and easy report creation. Or, create
reduces report development time, simplifies
person over a Web portal. Built-in security
your own report templates in minutes.
report modifications, and empowers users to
makes it is easy to define who has access
transform raw data into usable information.
to reports and who can create, modify, or
Create visually appealing and informational
generate reports. Even customise these
reports using data driven tables, pie
setting on a per-report basis.
modifications. • Industry report templates are included for
charts, bar charts, XY plot charts. Custom
How simple can it be? Drag and drop ‘intelligent’ report objects into the Report Template, the data
reports can be created easily, quickly,
Easily comply with regulatory and internal
manipulation is done for you. It’s that simple.
and inexpensively and made available to
Unique statistical objects make is easy
anyone, anywhere, anytime because it
to extract specific processes metrics and
includes a web portal. Wonderware HMI
perform data analysis.
Reports includes simple integration tools for easy data extraction from InTouch HMI, Wonderware Historian/IndustrialSQL Server, and any data source using OPC, OLEDB, ODBC, as well as other HMIs.
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Figure 1: Object toolbar
Information Dissemination: Wonderware HMI Reports
In a nutshell ...
See Figure 1 Wonderware HMI Reports is the most intuitive and easy-to-use reporting solution available on the
Intelligent report objects can automatically generate:
market today. It gives you the power to quickly and easily create reports from Wonderware InTouch HMI and many other data sources. Wonderware HMI Reports requires no IT or programming skills to design, schedule and produce appealing and informative dynamic reports. You can easily configure
• Current value
HMI Reports through simple drag-and-drop operations within the Report Studio. The design Studio also gives you ease-of-use features such as intelligent report objects and friendly dialogue boxes.
• Last value Wonderware HMI Reports will help you significantly reduce report development time, simplify report • First value
modifications, and empower you to transform raw data into great looking, information-filled reports. Custom reports can be created easily, quickly and inexpensively, with scheduling tools to help you
• Minimum value
deliver them to anyone, anywhere, anytime.
• Maximum value
Wonderware HMI Reports works with Wonderware Information server or an included web portal to extend the availability of reports throughout your enterprise network and beyond.
Business value • Weighted Average • Reduce time and effort to create, distribute, and revise reports • Sum • Quickly and easily transform raw data into great looking reports • Integral • Requires no IT or programming skills • Duration • Make reports available easily and securely on the Web portal. • Uptime
Key benefits • Downtime • Reduce time and effort to create, distribute, and revise reports • Runtime • Create reports significantly faster than Crystal Reports or Excel • On Counter • Quickly and easily consolidate your InTouch or Historian data into concise, visually-appealing • Off Counter • On/Off Counter
reports to better understand your processes and your business • Configure through simple interfaces, menus, intelligent report objects, and friendly dialog boxes. Requires no IT or programming skills.
• Status • Make reports available easily and securely to any authorised person with the built-in Web portal • Alarm Counter
Key capabilities • Logged Counter • Enjoy versatility - Intelligent Report objects include data-driven Tables, Pie Charts, Bar Charts, Line • Availability • Deviation
and XY Plot Charts • Easily define who has access to reports and who can create, modify, or generate reports with built-in security. You can even customise these settings on a per-report basis.
• Timestamp • Generate and Distribute custom reports automatically in Excel, Adobe Acrobat format (PDF) and • SQL Query
email format • Configure reports to be generated based on Events (e.g. Batch Complete), Schedules (e.g. Shifts) or on demand (ad-hoc)
Wonderware HMI Reports offer multiple options to extract Data and Alarms in different tables. Users can select
• Easily extract data from InTouch, Wonderware Historian/InSQL, and any data source using OPC, OLEDB, ODBC, including other vendor HMIs
May/June 2012 | 29
time frames to visualise and compare results fast (production and processes). The
• Wonderware HMI Report Studio: develop and configure report projects
chart objects support different types of data value, average value and linear regression. Users can display and adjust
• Wonderware HMI Report Run Time: execute report projects
multiple scales automatically or manually. • Wonderware HMI Report Generator:
Report Formatting Objects
generate new reports on demand
Customise the look of your report. Drag
• Wonderware HMI Report Web Portal:
and drop simple formatting objects for
access reports from a web browser
date and time, project name, report name and page numbers.
Wonderware HMI Reports Studio
the SQL table.
Time and batch-based reports
STEP table enables users to extract and
The Invensys Customer First Services
enables users to develop multiple reporting
display analytics from any step period in just
Programme makes it easy to receive
projects. The Studio is divided in two
a few clicks.
up-to-date Wonderware software and
sections, Logger and Designer, to facilitate
associated applications. To learn more
project engineering and protect critical
There’s even a ‘FREE’ Table object that gives
about this valuable programme, which
configuration such as communication
you freedom to customise as much as you
maintains and often increases the value
of your industrial software applications,
preformatted tables or create their own with
Wonderware HIM Reports Studio is multilingual and secure software that
please contact your local Invensys sales
Bar and Pie Chart Objects
Wonderware HMI Reports Bar and Pie
Logger Studio Using Logger studio, connect HMI Reports
charts allow users to display various
to any Smart Device, any RTU, PLC, but also to any manufacturing application such
statistical values and Alarms in clear views
Wonderware HMI Reports enables the
as SCADA Systems, DCS Systems, MES
with advanced visualisation (%, legend and
archiving of data in specified databases for
applications and more. It can also leverage
further Enterprise Information Integration.
any data logged in any standard database.
XY Charts Objects
With HMI Reports Logger Studio, users
Users can define time-based values on XY
Wonderware HMI Reports unique user
sources to finally aggregate all their data
charts. They can combine charts from different
in one strategic information management
can mix real time and historical data
application. The Logger studio also allows users to visualise all real-time data exchanged between Wonderware HIM Reports and the data sources.
Designer Studio The Designer Studio offers an intuitive interface with powerful toolbars enabling users to easily create accurate and visually appealing report templates. All data extraction is done with the HMI Reports Object Toolbar. This object library integrates dedicated Object for industrial automation reports. Also, define the generation and distribution report settings for each individual report.
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Information Dissemination: Wonderware HMI Reports
Wonderware HMI Reports Run-Time Reporting projects are executed by
• Optionally, Wonderware HMI Reports
display PDF reports from the current running
and to generate new reports over the
project or generate new reports on demand
using Web DRG. Also, it can be customised
Wonderware HMI Reports Run-Time. It also enables users to select any report and
and integrated with other web portals.
Dynamic Report Generator
generate it instantly with the latest updated values.
Authorised users can easily browse and
Web Portal to visualise all reports archived
Wonderware HMI Reports Web Portal With Dynamic Report Generator (DRG),
is ideal for improving global asset
authorised users can select any report
management and facilitating business
template running in Run Time and generate
decisions by providing proactive up-to-
a new report “on demand” instantly. This
date reports. It can be used by operators,
module is available as a standard windows
managers and executives as well as
application, a Web application, and as
customers, organisations and suppliers that
an Active X component to be integrated
elect to be permanently connected and
• Data acquisition of real time sources
into InTouch HMI applications.
interact with the field. And because HMI
• Data logging in any standard databases
• Generate reports with original settings to
Wonderware HMI Reports runtime manages: • Security and all access rights
Reports is multi-lingual, the Web Portal can (by default MSDE)
be used across the globe.
get up to date values It enables any authorised user to:
• Data extraction from Historians or from Wonderware HMI Reports History
• Or generate reports with modified settings such as custom time period,
• Visualise all reports archived
relative time, fixed period, or per batch • Permanent calculations of all analytics
• Generate new reports on demand
defined in reports • Proactive report generation
Wonderware HMI Reports Web Portal
• Automatic report distribution
Wonderware HMI Reports Web Portal is
• Change report settings before generation
ideal for distributing and sharing reports • Dynamic Report Generator to generate reports on demand
over the Internet/ Intranet. Customised security manages access rights for users.
May/June 2012 | 31
The power is in the innovative design
any standard database such as Microsoft SQL Server, Oracle, or MYSQL Access.
Report Generation and Distribution
This unique feature positions HMI Reports
HMI Reports enables you to generate
not only as a reporting tool, but also as the
reports manually and automatically. The
HMI Reports integrates a robust
ideal solution of field data integration for
automatic mode executes reports on
communication kernel to collect data and
event and on schedule. Reports can be
alarms from InTouch HMI and Wonderware Historian, as well as other data sources. It
automatically printed, emailed, stored and
Data Extraction and Analysis
uses OPC, OLE and ODBC standards to connect and collect data from different
HMI Reports integrates a user friendly
suppliers. In addition, special drivers
object library to extract data statistics and
are included to leverage native history from
analysis to be displayed in multiple views like
SCADA systems, DCS, RTU, other HMIs, and
tables, bars, pies, charts and more.
Report Design Data Logging HMI Reports studio module integrates an HMI Reports integrates an historical
intuitive graphical editor to create and save
database to log clean and accurate data in
state of the art reports as templates.
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Information Dissemination: SmartGlance and Wonderware Mobile Reporting
Information Dissemination: SmartGlance and Wonderware Mobile Reporting
Today’s complementary communication and computer technologies mean that you need never be far away from anyone or anything – one of those things being your manufacturing plant. Now you can be as informed as anyone on site wherever you may be.
Wonderware Mobile Reporting is comprised of
leverages this technology so your plant data
SmartGlance, Sarla Analytics’ smart
is always available on your phone.
phone reporting service and the Wonderware Mobile Reporting Connector, which provides
Many of today’s top companies are
data connectivity to the Wonderware Historian
using cloud computing to provide their
and other data sources.
workers with important company information in a highly cost effective and secure
Working together, data reports are sent to
manner. SmartGlance leverages the cloud to
your phone and are updated automatically,
provide you with critical plant performance
so they are ready when you need them.
data at the lowest possible cost.
SmartGlance supports state-of-the-art
Smart decisions, anywhere, anytime
mobile devices as the Apple iPhone, iPad, iPod Touch and many of the Blackberry
Key capabilities of mobile reporting
devices. Android and Microsoft Phone 7 are Imagine having access to your most
also on the way.
Critical data at your fingertips
Innovative technologies drive mobile reporting
SmartGlance connects your mobile phone
important plant floor data from anywhere, at any time, using your smart phone. Not browser based reports with their inherent delays and viewing problems, but a native
with any corporate or production system data source. Virtually any electronic data
phone application that presents your
Two of today’s hottest technologies
t hat is delivered to your desktop can be
data in a format you can easily read and
drive our Mobile Reporting solution –
transformed into a graphical report for real
manipulate using your phone’s screen
cloud computing and smart phone apps.
time viewing on your mobile smart phone
Just about everyone has a smart phone
or device. There is no limit to the number of
today and the SmartGlance phone app
reports or number of rows in a report.
May/June 2012 | 33
In a nutshell ... Decision makers and mobile workers in the process, power and manufacturing industries can stay informed of their facilities’ operational performance through SmartGlance reports. Wonderware Mobile Reporting is comprised of SmartGlance, Sarla Analytics’ smart phone reporting service and the Wonderware Mobile Reporting Connector, which provides data connectivity to the Wonderware Historian and other data sources. Leveraging two of today’s hottest technologies, cloud computing and smart phones, SmartGlance can send reports to subscribed smart phones automatically or on-demand. SmartGlance reports are always fresh and ready to use. Our secure, cloud-based data server eliminates the need for costly local data servers so you can get your whole team receiving SmartGlance reports without a major IT investment. The SmartGlance phone app also takes full advantage of the powerful touch screen navigation features of today’s smart phones so reports are easy to read and easy to navigate. No “keyhole” effect common with web-based reports. SmartGlance supports state-of-the-art mobile devices like the Apple iPhone, iPad, iPod Touch and many of the Blackberry devices. Android and Microsoft Phone 7 are also on the way. You can try SmartGlance on your own smart phone by going to either the Apple App Store or Blackberry App World and downloading the free phone app. Just search for “SmartGlance”. Once you install SmartGlance you will be able to view demo data and learn how easy SmartGlance is to use.
Key benefits • Improved operational awareness • Improved decision-making • Accelerated troubleshooting • Enhanced collaboration • Improved agility • Lowered costs
Key capabilities • View real time or historical data reports • Critical KPIs and Reports available anywhere, anytime • View KPIs, track changes, take action • Powerful, analytic displays for easy troubleshooting • Arrange, sort and filter reports based on • Supports powerful touch screen navigation
• Email reports or graphs to colleagues
• Secure, low cost cloud-based report generation and delivery
You choose which reports you want and view them as tables, pie charts, bar charts, line graphs or other formats. SmartGlance displays your information in a graphical format optimised for the small screen of your mobile phone without having to scroll left and right to view the entire report. Simply swipe the screen to view the next report.
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Information Dissemination: SmartGlance and Wonderware Mobile Reporting
• Automatic data updates • Connect to any SQL compatible database • View familiar report styles • 24 x 7 access from anywhere
In-depth analysis SmartGlance uses the convenience of your smart phone “touch screen” functions (if available) to let you manipulate your graphs or charts for further analysis. You can zoom into areas of interest or zoom out to see the big picture. You can even view two reports or two elements within a report at the same time for easy comparison. • Powerful touch screen analytics • Easily compare your data with Target or
• View rich graphics – tables, line charts, bar charts, pie charts
• Choose and expand data element s to
identify trends • Instantly flip through hundreds of
• Optimised for easy viewing on a small screen
• Compare data by time, data, or other criteria
reports comparing data to help pinpoint problems
• No left-right scrolling to view reports • Customise reports
Tools to take actions
• Share reports with your colleagues
Share feature allows a report or data graph
• Navigate using your phone’s native ”touch” features
to be sent by email to someone else on your • Versatile viewing options
Make more informed decisions
team. So, regardless of where you are, you can initiate action on a potential problem. Another feature is a dynamic “i” button
Just because you aren’t in the office, you
that provides hot links to a phone number
SmartGlance delivers data from your data
shouldn’t be at a disadvantage. This is
or email address of a specific person.
sources to your mobile phone in real-time.
the power of SmartGlance. Make better,
Operating procedures/instructions or a
SmartGlance displays up-to-the-minute
more informed decisions based on real-
system diagram can also be made available
information so you always have the most
time information accessible from anywhere,
through the “i” button via a web link (URL).
accurate information on hand. SmartGlance
at anytime. While you may be on the road or
can also be configured to automatically
away from your office, your critical business
update the screen while you are viewing it.
information is always available.
May/June 2012 | 35
“SmartGlance, with its user-friendly interface and powerful analytics, gives our core leadership team up-to-date information and analytics of our business. Our team count on this information and take decisions that have a positive impact on our business.” Adi Shroff, CIO and Sr. VP, Corporate Human Resources, Eureka Forbes
“We are very pleased with the support and training we got from SmartGlance. They have made it easy for us to bring the solution to our customers...” Dave Wilson, Software Application Specialist, Process and Data Automation
Authentication SmartGlance users achieve authentication by registering the phone hardware with your login in the service. This registration ensures that only a “Registered and Authenticated” phone can access the SmartGlance service. Each communication message has built-in authentication.
Authorisation Mobile-Level authorisation – In addition to device authentication mentioned above,
Administration of users and user groups
the user must be authorised to use the
is also included enabling specific users or
service. Unless a user has a password, they
user groups to receive only the reports
will not be allowed to use the service and
related to their job function. The cloud-
access data. So, the user must log in from
based SmartGlance SaaS Business Report
their registered and authenticated phone
Generator then manages the secure delivery
and must have their password to access
of the prepared reports to authorised
the service. This level of authorisation is
The Wonderware Mobile Reporting Connector
mobile devices for real-time data review and
particularly important if the user loses their
provides report configuration, formatting and
Wonderware Historian data is supported along
The Wonderware Mobile Reporting
with data from any ADO.NET compatible data
Connector is fully supported by
source for enhanced data access to third party
Wonderware’s award winning Technical
When your system administrator sends plant
data to SmartGlance’s hosted service, they
Data security features are built-in and
Wonderware mobile reporting connector
data connectivity services to SmartGlance.
are required to enter the email addresses the connector allows easy browsing and
of authorised viewers. So, each report that comes to the host system will have a list of
selection of data tags for SmartGlance
Today, data security is a primary concern.
email addresses that are authorised to view
reports from multiple Historians – no special
SmartGlance has been developed using
that report. So, if a user is not authorised to
SQL queries are needed saving valuable IT
the three pillars of secure connectivity
view a particular report, their email address
resources. The connectivity is robust with
– Authentication, Authorisation and
will not be in the report.
“Store and Forward” functionality built-in to
ensure that only complete reports are sent
to your smart phone. All SmartGlance data is encrypted (128 bit encryption) prior to transmission to ensure security. The SmartGlance SaaS Business Report Generator hosting service operates under full encryption using a secure site (HTTPS) verified by a third party (VeriSign Thawte) security certificate. Additionally, all data aggregation for your SmartGlance reports is done within your internal network and behind the firewall.
Other options If a non-hosted approach is required, a secured plant-wide Wi-Fi network can be used as an alternative to cellular networks to still enable mobile reporting within the confines of the facility. This solution, although requiring a higher investment in IT resources and capital, would still allow
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Information Dissemination: SmartGlance and Wonderware Mobile Reporting
the benefits of a SmartGlance Mobile
• Custom Ad-Hoc SQL Query support
Reports implementation, while keeping all
for Wonderware MES, Wonderware
data exchange and mobile reporting in a
Intelligence, Wonderware Corporate
Energy Management (CEM) or other Microsoft SQL based database
Supported mobile devices
Where to learn more
Apple Products: Already have an iPhone, iPad or Blackberry? Start using SmartGlance right away! Log into the Apple App Store or BlackBerry App World directly from your phone and search for “SmartGlance.” Download the app (iPhone or Blackberry) and log in as a registered user with the following credentials: • BlackBerry Curve 8300, 8310, 8320, 8330,
• Username: email@example.com
8350i • iPhone – 2G, 3G, 3GS, 4,
• Password: password • BlackBerry Curve 8500, 8530, 8520
• iPod Touch – all versions
For more information on how the • BlackBerry 8700, 8703e, 8707
SmartGlance Reporting Solution can help you, visit www.smartglance.com.
• BlackBerry 8800, 8820, 8830
SmartGlance is also available on Facebook, Linkedn and Twitter
• BlackBerry Curve 8900 and 8910
Conclusion • BlackBerry Curve 9300, 9330 The SmartGlance Mobile Reporting Solution • BlackBerry Bold 9650, 9700, 9780
is a convenient and simple way to bring meaningful real-time plant intelligence to
• BlackBerry Tour 9630
both production workers and executives in your organisation who already use smart
• BlackBerry Storm 9500, 9530
phones and mobile devices.
• BlackBerry Torch 9800
The hosted solution keeps your data safe and protected and is easily scaled and
Supported data sources
modified without the need for additional infrastructure investment to support your
Windows Phone 7 devices
• Native support for Wonderware Historian
ongoing or future information needs.
V9.0 and V10.0
May/June 2012 | 37
Information Dissemination: Remote Response Objects
With increasing demands on time and
resources, Wonderware Remote Response Objects enable alarm and event information
• Build as ArchestrA Objects –
to be delivered to your mobile and offsite
allowing for easy extension to
engineering personnel, keeping them
your existing application
informed of significant production or process changes regardless of their location.
• Email and SMS (via appropriate gateway) support
By integrating the two most common mobile message based technologies (email and
• Operator response
SMS), your engineers are never more than a
(acknowledgement) via email
handset away from being informed and able
to acknowledge critical events. • Low cost Incorporating a powerful yet easy-toadministrate scheduling system, your
operations staff are in contact 24 hours a day, and escalation rules give built-in backup
• Built-in scheduler
notification for super visors and reserve personnel.
• PIN-based security option • Configurable escalation in case of non-response • Operates with redundant (failover configuration) of System Platform
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Information Dissemination: Wonderware SCADAlarm alarm and event notification software
Information Dissemination: Wonderware SCADAlarm alarm and event notification software
SCADAlarm serves as a telecommunications
and deployment of messages, 24/7, can
SCADAlarm software intelligently vocalises
link to industrial automation software
significantly reduce personnel costs and
alarms over speakers, intercom systems,
systems. SCADAlarm software provides
improve response times.
radios and telephones. It can also send
real-time intelligent al arm notification, data acquisition and remote control from a multitude of telecommunication devices.
alphanumeric text messages and/or e-mail. • Speed – Users can quickly gain remote access to live information.
As an enterprise-wide telephony and messaging system, SCADAlarm software
Users telephone in and, after acquiring authorisation from the security system, can receive privileges to remotely respond to
• Reliability – SCADAlarm software has
alarms. SCADAlarm software enables the
can transform any PC into a communications
a proven track record for reliability with
user to navigate through secure voice menus
command centre that can monitor the
some of the most prestigious corporations
entire network 24/7 and deliver the right
in the world.
information to the right person at the right time.
• Listen to and acknowledge alarm details
Powerful remote alarm and event management
• Change analogue tag values and/or discrete tag states
SCADAlarm software is the most powerful • Convenience – Users can interact with process systems from any telephone.
and flexible product of its kind, ushering in a new generation of intelligent alarming.
• Access HMI and/or Industrial Application Server information
Wonderware’s popular SCADAlarm • Freedom – Alarm information can be
product is unique because it’s not just an
accessed from any HMI or the Industrial
alarm-and-event messaging system, but an
interactive extension of human-machine
interface (HMI) software systems and the
TAPI (Telephony Application
Wonderware Industrial Application Server.
Programming Interface). This is a Microsoft
• Cost Savings – Continuous monitoring
May/June 2012 | 39
In a nutshell ...
programming standard that enables telephony software to work with any TAPI-compliant modem. As a result, SCADAlarm software is device-independent and allows users to choose standard, inexpensive
SCADAlarm alarm and event-notification software provides a
off-the-shelf modems in their local areas. In addition, users benefit from
telecommunications link to industrial automation software systems.
a host of other features such as:
SCADAlarm software seamlessly integrates with the comprehensive
• Support for standard RIFF (or .WAV) files
Wonderware product family and has built in browsers to enable fast configuration of information from Wonderware System Platform and InTouch
• Audio files leverage the latest technology
HMI software. • No VOX conversion required Alarms can be vocalised over speakers, intercom systems, radios, multimedia speakers, PA systems and telephones. Users can listen to and
• Simplified audio recording
acknowledge alarms, change set points, hear exact values of variables, and operate equipment via telephone from remote locations, saving valuable
• Local annunciation over multimedia hardware
time and money. Included in the SCADAlarm product case is a tested fullduplex voice modem to enable you to get up to speed right out of the box.
• Support for multiple-channels
SCADAlarm is an essential tool for SCADA systems in all fields, from Water
• Multiple modem support for one SCADAlarm system
and Wastewater through Facilities Management to general plant alarm automation.
• Independent device configuration
• Modems can be configured independently for different uses, such as incoming and outgoing calls Setup for using TAPI is as easy as
• Remote Alarm Notification for geographically isolated workers
installing and configuring the modem’s driver.
• Reduce need for 24 hour staffing at all facilities
Wide-ranging industry applications
• Local voice annunciation for plant-wide status broadcasting
Industries around the world are realising the benefits of SCADAlarm software and achieving a new dimension in remote connectivity,
• On-demand information on process conditions and variables
• Included PCI modem tested and validated for use with SCADAlarm
• Water, Wastewater, Oil & Gas - Redundant SCADAlarm systems monitor manned and unmanned plants, pipelines and offshore oil
Key capabilities • Text-to-speech capability for maximum flexibility
rigs 24/7. • Pharmaceutical - Plant personnel broadcast process-quality information over pagers and plant PA systems.
• Multiple delivery mechanisms (phone/voice, PA/speaker, pager, email etc.)
• Building Automation - Operators can adjust temperatures, turn lights on and off, and receive and acknowledge security and fire
• InTouch HMI and ArchestrA alarm acknowledgement capability • Voice recorder allows maximum customization
alarms from telephones. • OEMs / Machine Builders - The software alerts maintenance personnel about machine malfunctions.
• Flexible scheduler allows message delivery based on shift, day or time
• Semiconductors - SCADAlarm software can be used in gasmonitoring systems. The simplicity and flexibility of Wonderware’s SCADAlarm software has enabled thousands of customers to realise the power of advanced telecommunications for their unique applications. The application possibilities are virtually endless.
ArchestrA integration SCADAlarm software is an integral part of Wonderware’s ArchestrA technology for industrial automation. SCADAlarm software includes built-in browsers that can connect to Wonderware’s award-winning
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Information Dissemination: Wonderware SCADAlarm alarm and event notification software
Support for caller ID Security is a primary concern when implementing systems that enable control via external devices. Version 6.0 expands the capabilities for increasing system security by supporting Calling Party Identification (CPID). This feature increases flexibility and security when authenticating callers, such as: • Automatic logins based on the caller’s phone number • Restricted logins based on the caller’s phone number • Hacker detection InTouch HMI and the Wonderware Industrial
SCADAlarm 6.0 software supports text-
Application Server software systems to
to-speech technology. Now, instead of
enable faster system configuration.
manually recording voice files, you can
• Restricted access if no caller ID is presented
generate sound output directly from SCADAlarm software can be configured
text and save a tremendous amount of
to alert operators to more than just alarms.
configuration time. The text-to-speech
For example, a message to the operator
capability can also help you standardise your
can be sent when someone generates
company’s text and audio messages.
about inventory levels, part numbers,
Integrated industrial application server features
options, including supervisory e-mail acknowledged and/or cleared • Support for global alphanumeric paging
supplier contact information, etc. to personnel on the plant floor.
• Extensive e-mail support and notification reports when alarms are activated,
an emergency work order. In addition, SCADAlarm software can send information
The Wonderware Industrial
Application Server and SCADAlarm SCADAlarm software combines
software are a winning combination for
the convenience of mobile communications
quickly alerting personnel to changes and
with the power of Wonderware -
alarms in the control system. SCADAlarm
giving you control, information and
Version 6.0 enables native communication
intelligent messaging at your fingertips.
to the Industrial Application Server using MX and a built-in attribute browser for
Additional features Text-to-Speech
• Four contact devices per operator • Enhanced Tag-Vue spreadsheet provides convenient alarm editing and sorting • Aware of Wonderware’s SuiteLink and
fast configuration. Industrial Application
DDE (Digital Data Exchange), OPC
Server Alarm Acknowledgement Alarms or
(in conjunction with OPCLink) and MX
events that occur in an Industrial Application
Server system can be acknowledged easily through a new configuration window in version 6.0 of the SCADAlarm
• Integrated logger can e-mail SCADAlarm log file at scheduled intervals
software. Plant personnel can acknowledge and listen to alarms and events using all the standard
• Content-sensitive help at any time by pressing F1
SCADAlarm methods. • Alarms broadcast over speakers,
InTouch batch tag imports
intercoms, PA systems, radios and multimedia sound systems
SCADAlarm 6.0 software includes an InTouch tag browser that supports batch import of InTouch tag definitions into the
• Alphanumeric and numeric messages to pagers and mobile telephones
SCADAlarm software, enabling faster configuration of alarms and events.
May/June 2012 | 41
The route to a simple solution is usually extraordinary Get an end to end solution tailor-made for your business with Business Connexion’s Professional Services When it comes to making extraordinary connections, nothing comes close to the human brain. That’s why it’s the inspiration behind our Professional Services. With our unique understanding of your business model, value chains and strategy, we can supply you with an end to end solution that helps you make the most of your Business Processes, Applications Portfolio, Application Management and third party solutions. With our unique integrated solutions, we can help you build systems that enable you to enhance and grow your business. We call it the amplifying power of Connective Intelligence™.
www.bcx.co.za 42 | www.protocolmag.co.za
May/June 2012 | 43
• Voicemail menus simplify the
SCADAlarm Demo Version
The following minimum system requirements
SCADAlarm software includes a
“demo version.” This is simply a pre-
manipulation of industrial automation software systems • Works with all major software systems and Wonderware’s Industrial Application
configured SCADAlarm application that • At least 100 MB of free hard disk space
can select to install the demo version • At least the minimum amount of RAM
• Contains system scheduler for all the days
required by the operating system
of the week and holidays
during the installation. If you have a valid SCADAlarm license installed, the demo version will run until the license expires. If
• Any of the following Microsoft operating • Alarms can be grouped and prioritised
includes a simulated pager/phone. You
not, the demo version will shut down after
Windows XP Professional, SP2
Windows 2000 Professional
The following software packages have
individually • Human voice recording in any language • Multiple operator clearance levels
been tested and are supported by Windows 2000 Server
Wonderware’s SCADAlarm software:
Windows 2003 Standard Server
• Wonderware InTouch 9.0
• Extended on-call, back-up and courtesy notification groups • Daily schedule and personal calling
• Voice modem that supports TAPI
preferences for each operator
• Wonderware Industrial Application Server 2.0
• Available EIA-232 Serial Comm Port • On-demand self-documentation • Text-paging terminal for operators to type
• Intellution iFix 3.5
• Available PCI or ISA slot (internal modem)
• Siemens SIMATIC WinCC 6.0
• Receiver (e.g., pager, e-mail server, phone)
• Rockwell RSView32 6.3
• 800 x 600 video resolution or higher
• Ci Technologies CiTect 5.40
and send messages to any pager • A single SCADAlarm system can monitor the entire LAN • Redundant configuration on Master and Standby nodes
44 | www.protocolmag.co.za
Staying competitive means continuously improving the assets of your plant, throughout its productive life. Invensys provides a path to keep your automation and control system continuously current with cost effective modernisation solutions, regardless of your systemâ€™s age or vintage.
Find out how Invensys can help secure your future: Logon to www.invensys.co.za for a whitepaper, brochure, customer success stories and migration video.
May/June 2012 | 45
Plant Information Management System at Petro Rabigh Orchestrating complex systems to work as one By Patrick D. Murray, Principal Engineer, Invensys & Yadukulatilakam Ramaswamy, Senior Director, Consulting Services, Invensys
46 | www.protocolmag.co.za
Plant Information Management System at Petro Rabigh
1. Abstract The refining of crude oil to produce fuels and petrochemicals encompasses a variety of process technologies. Automation systems used to manage these systems work to operate in a safe environment and to optimise production quantities and quality at a competitive cost. These disparate systems strive to reach a common goal by serving managers, engineers and operators but are extremely complex as each subsystem is best-in-class and focusing on a narrow aspect of the business. Integrating them into an enterprise-wide solution is often
Typically, the return on investment (ROI) from integrated Operations Management Systems is 6 to 12 months, but often the real savings is realised for years after the go-live date through the ease of implementing changes and adding additional systems. Want to add a backup pump for waste water disposal? Not a problem, just copy an existing template with most of the parameters installed
difficult. The InFusion™ Integration Infrastructure proved to be an ideal platform for the integration, orchestration and reporting/visualisation framework for this overall solution.
applications and KPIs within the InFusion environment are reviewed as described in the functionality of the InFusion Foundation edition
With such a powerful platform, the barrier between the business side
and the engineering and production side of the plant is completely removed. SAP, which is used to manage business data (such as
3. Project rationale and expected benefits
production orders, schedules and material costs), can now receive quality production data from the Operations Management layer through one seamless interface with the InFusion infrastructure. Such
Diverse systems working on their own (islands of automation)
high quality, reconciled production information and other operating parameters can also be used for performance management.
The Petro Rabigh refinery was similar to other large-scale processing plants with cell technology working well to complete its function but
This paper explains how the implementation of a Plant Information
unable to communicate well with other areas in the plant, much less
Management (PIM) System was integrated with SAP in one of
business systems. Obtaining discrete or analogue output to trigger
Invensys’ major customer sites in the Middle East. Winning this
an alarm or perform a function within that cell (such as PLC/SCADA)
ground-breaking project required a paradigm shift in changing the
has been the domain of the controls engineer. Sharing that data with
integration philosophy from using Real-Time Database (RTDB) as the
production control (ERP) is still somewhat tedious and the redundant
integration platform to using an object oriented, service-oriented
task of manually transferring data is fraught with opportunities to make
integration technology offered by InFusion. The customer understood
the benefits of using such an expandable and scalable architecture, which also allows user-modifiable objects to be developed remotely
The Petro Rabigh complex is similar to other large scale processing
and then integrated into the production environment after testing. The
plants that require robust integration of information to be
PIM System was implemented using best-in-class applications from
communicated between several entities within the organisation and
several vendors including Invensys integrated through the InFusion
Infrastructure. Time is critical in complex projects because the systems often become
obsolete before implementation is complete. This is where an open, object- oriented system allows the development continuum to proceed
Rabigh Refining and Petrochemical Company (Petro Rabigh), Saudi
as the InFusion model based on ArchestrA® does not need to be
Arabia, a Joint Venture between Saudi Aramco and Sumitomo
recreated each time a change takes place. Just a few years ago, the
Chemicals of Japan, took on the expansion of the original Topping
pressure gauge required that analogue signal conditioning be done
Refinery into a conversion refinery and a huge Petrochemical Complex
downstream in a feedback loop and be packaged entirely inside the
to produce fuels, monomers and polymers at a single facility with a
device. This is where the flexibility and power of ArchestrA’s open
vision to establishing itself as a world leader in the industry. With the
structure pays off. Unanticipated changes at the sub-system level are
commissioning date set for early 2009, they required the PIM System
easily handled with only a few mouse clicks.
integrated with SAP. The scope of the project was to develop the business processes supported by a suite of technologies to perform
The inseparable bond between time and money were key drivers in
planning, scheduling, operations management, production accounting
the customer selecting InFusion as the platform for enterprise-wide
and performance management functions in an integrated manner.
solutions. The global economy at the start of this project (October
The PIM System seamlessly integrates with SAP to perform the higher
2007) was demanding products, yet keeping cost in line with a lean
level business functions with reliable information from the refining and
budget was key. Fast-forward to the market collapse a year later,
product demand plummeted, necessitating agility to changing marketing environment. Now the decision to pick an infrastructure to
This paper briefly discusses the site-wide expansion and new
support this requirement with modular flexibility and providing reliable
development, focusing on the aspects of the enterprise management
information to the business system, makes the choice look even more
system and demonstrating the power of InFusion as the integration
brilliant and speaks volumes for the customer’s vision to adopt such a
infrastructure. The ease of setup, configuration and testing of the
May/June 2012 | 47
“Petro Rabigh’s key requirement was to integrate their control systems tightly with production and corporate business functions, thereby enhancing planning, scheduling, directing and managing activities across the Rabigh Refinery and Petrochemical Complex. The specifications called for a Real-Time Database (RTDBbased integrated solution while Invensys convinced them of the disadvantages of such an approach and proposed an Object Oriented, Service Oriented integration infrastructure which became the rationale behind the Customer’s selection of Invensys solution. We based our solution on Invensys’ flagship Enterprise Control System product, InFusion that integrates tightly with the specified Exaquantum real-time database and historian, while providing the integration, orchestration and reporting/visualisation framework for the overall solution. The InFusion-based PIM solution at Petro Rabigh enables consistent, accurate performance feedback – a key driver to consistent execution of the business. InFusion’s open, structured but user-modifiable object oriented architecture precisely fosters this: ongoing changes can be centrally effected and remotely deployed to keep the system always up to date, with the expertise of internal resources encapsulated and automated within the system. In our experience, Invensys PIM solutions have demonstrated consistent ROI – sometimes paying for themselves in as little as 6 months, but with 12 months being the norm. By harnessing the capabilities of our proven industry solutions under a single, integrated environment, Invensys’ solution provides Petro Rabigh significant improvement in the management of its Rabigh Complex and substantial financial savings into the future.” Yadukulatilakam Ramaswamy, Invensys, May 2009
comes on line, it will be able to produce 2.4 million tons/year of polyolefin’s petrochemical derivatives.
Geography Lately, you hear the term ‘Global’ used quite often; With a customer located in Rabigh, Saudi Arabia, the development team located in the Netherlands, with concurrent efforts taking place in the US, HyderabadIndia, Dubai, Tunisia and Montreal, this project took on a legitimate ‘global’ claim. Invensys is no stranger to global-sized projects, yet bringing the best people and technologies together was quite unique. The decision was made to centre the team in the Invensys Advanced Application Services Division, located in the Netherlands where the applications developers, programmers and managers could collaborate and communicate. Quick and easy solutions were reached with input from the site in Saudi Arabia. Additionally, east and west locations could be coordinated in a balanced time zone, using web meetings.
5. Solution Highlights Figure 1: ArchestrA model
The breadth of a project of this magnitude took a great deal of
4. The Refining and Petrochemical Complex
coordination between different team members. Everyone working on different applications to the same set of development standards,
New build for capacity
specifications and drawings required close coordination and good communication.
The Rabigh facility is an upgrade of an existing 400 MBD topping refinery and construction of a new petrochemical complex. A range of refined products (130 million bbl per year) will be produced including, gasoline, diesel, fuel oil, naphtha, jet fuel and kerosene. This showpiece upgrade includes the high olefins fluid catalytic cracker complex integrated with an upscale ethane-based cracker. When this facility
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Plant Information Management System at Petro Rabigh
Figure 2: An overview of the Petro Rabigh facility
The following is a list of applications constituting the integrated
• Data Reconciliation
solution coming online at rollout of the PIM System: • KPI collection and calculation • Data Acquisition and Historian • Integration with SAP • Alarm and Event Monitoring While all sub-systems were included in the setup of the integrated • Plant Data Modelling
system, only the last four items are discussed in further detail below in order to keep the length of this paper within reasonable bounds.
• Mass and Energy Balances including data reconciliation
InFusion, the right tool for the job • Plant-wide material balance and production accounting Today, the need for platform-independent solutions can’t be • Tank Information System (TIS)
overemphasised. Alliances have been formed and the lines drawn but these relationships last only as long as the project they are serving and
• Order Movement Management (OMM)
customer needs are met. These dynamics are even more pronounced in the commodity market such as petroleum products. The choice
• Laboratory Information Management System (LIMS)
came down to the static uniformity of using one vendor’s suite or the flexibility of picking the best-in-class solutions for each application from
• Operations Logbook
• Emissions monitoring
Invensys’ InFusion object and service-oriented framework has proved to be an ideal platform that had the flexibility of easily
• Downtime monitoring
modified objects that showed remarkable promise for adapting to the dynamic environment within the market. Both solutions
May/June 2012 | 49
“Petro Rabigh’s first priority was the collection of production progress data needed to fulfil the SAP data requirements. The result shows that the data in SAP is much more reliable than manually-entered data. To achieve this, the production tracking module collects data from various sources (such as DCS, TIS, and OMM) and, using an object-oriented plant model, transforms this into production tracking data, like materials consumed and produced per production order and a history of tank levels. The mass balancing applications (MBM and GERA) then serve to enhance the quality of the data by validating its consistency and applying, statistically plausible corrections to the raw data. Any inconsistencies, which cannot be explained by the known inaccuracy of the various meters and sensors, are signalled and corrected manually by the production accountant. The result is a set of formallyapproved and consistent data, which is sent to the SAP system. Furthermore, the PIM system supports the daily operation in reporting various production events (such as start/end of importing/shipping and product tank filled) which, among others, automatically instruct the lab to take and analyse material samples. In the near future PIM will also serve as a source of data for an advanced planning and scheduling system, which will convert the rough monthly planning in SAP to a daily production planning. The results of this planning will be sent to PIM to be shown as operator instructions in the operator logbook and as a basis for the creation of planned orders in the OMM system.” Udo Zwart, Senior MES Consultant, May 2009
Control Systems) and SAP. These interfaces are defined in the design specification’s internal interfaces.
6. PIM System – functional overview The InFusion integration layer is the core to the PIM System and access to all PIM applications listed above, data storage and retrieval are available from this domain. The data definition is done in the InFusion Engineering Environment (IEE). The real-time data from the Process Control Systems and the Utilities plants, IWSPP are received in the PIM system through an OPC interface and stored in the Data Acquisition and Historian System (DAHS_ Exaquantum). The legacy data from an old PI system in the Refinery was migrated to the DAHS, with the DAHS as the primary storage of process data. Only the data is required by applications that connect to InFusion; objects are copied from the InFusion Environment. The particular application that requires DAHS data, accesses the specific InFusion object, representing the data. Real-time data required by the applications is made available using InFusion Data Access Servers (DAS). The OPC and required historical data are retrieved using an InFusion proxy to retrieve the data. Both of these methods are transparent to the users of the data. The results are created by an application and stored in the InFusion Historian. The functionality of the supporting applications is tabulated below. Each application is fully autonomous, has the interconnectivity capability without the need of OPC setup, and has the uniformity of design from the ISA-95 protocol. These systems where configured independently and then incorporated into the InFusion integration environment. This flexibility of InFusion enabled concurrent design efforts while ensuring that all systems met the customer’s requirements in design and testing. The PIM system has a unified user interface which provides access to all PIM System applications. A web environment is used to display mimics and trends in which a combination of overview (InFusion) and detailed mimics (Exaquantum) and trends may be viewed and analyzed. A series of predefined reports may be created using the reporting interface. The data are collected using ‘SQL-stored procedures and views’ and formatted by InFusion Reporting (based on the Microsoft SQL Server Reporting Services infrastructure). The final result can be stored as various types of files (PDF, Word, Excel, HTML, etc.) and displayed
work to integrate the production and business operations sides of
in the web environment. The stored files may be accessed later on
the business, but the difference is in how this was achieved. The
demand. Stored MS Word files can be edited or combined into new
InFusion model uses a bridge layer from operations in the structure
reports by the user.
that lends endless capabilities for modular expansion and works with real-time data requirements and historised data, while meeting the
Plant model design conventions
requirements for conformance to standards (such as ISA-95). OMM, TIS, SAP and LIMS now have the flexibility to bolt on additional
The basis of the PIM System design is the ISA-95 terminology and
plant model concept. Using this model, the site can be regarded as built from areas and production units, process cells and units. ‘Units’
in the ISA-95 structure can be part of only one plant. However, the Petro Rabigh structure may have a unit defined in several Plants. For
Figure 3 shows the functional components of the PIM System. They
example, CT_123 (cooling towers unit) is part of five different plants.
communicate with each other and relate to the external systems
In the InFusion plant model, the CT_123 unit has been separated into
IWSPP (Independent Water, Steam and Power Provider), PCS (Process
sub-units, each belonging uniquely to one plant. The unit name of the
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Plant Information Management System at Petro Rabigh
Figure 3: System architecture
sub-unit is created from the unit name by adding an underscore (such
structure to allow information to flow from the subsystems and field
as CT_123) and mnemonics to specifically identify the plant. In the
devices into the DCS and Historian. The performance monitoring
InFusion plant model, the sub-unit is used and accessed just as any
system is the feature diagnostic and analytical area of the system.
plant unit. Petro Rabigh truncated the industry standard ‘KPI’ to ‘PI’ as they saw no ISA-95 is the standard for the integration of enterprise and control
significance in monitoring an unimportant performance indicator. The
systems. ISA-95 consists of models and terminology used to determine
areas of focus for traditional disciplines (such as quality, cost, schedule
which information must be exchanged between systems for sales,
and safety) can be distinguished at the user level through reporting and
finance, logistics and systems for production, maintenance and quality.
This information is structured in the UML models and provides the basis for development of standard interfaces between Operations
System Engineers made this build very simple with spreadsheets that
Management and ERP systems.
were used to lay out the design intent from design specifications then search the Exaquantum historian to find the input tags to generate
7. InFusion – Easy to use and a flexible platform
the parameters necessary for InFusion to create an output (such as trigger an alarm for H2 consumption – too high, as shown in table 2). The spreadsheets where then used to generate performance indicator
The ease of use and flexibility of InFusion can best be described by
templates. InFusion allows the engineer to build, assemble and design
understanding performance as illustrated in the following example:
requirements and specifications into standard instances (such as a template in the InFusion environment).
$PI Performance Indicators Once the template was ready, all configuration information (such as $PI The inherent flexibility to adapt to changes in the system will provide
name, the unit it belongs to, input tags and alarm limits) was populated
future benefits to the system expansion and scaling. The PIM System
into a spreadsheet. The text format or *.csv (comma delimited) files
initial build required a systematic approach to extracting information
were imported into the InFusion Platform resulting in ready- to-run $PI,
from the process flow diagrams, specifications and building the tag
called instances in InFusion.
May/June 2012 | 51
Balance LIMS organises
The complex wide
mass and energy
processes into one
balance and data
or PI’s) are
Analytical data is
in the InFusion
entered, stored, and
run every day to
managed in LIMS.
SAP QM IDI serves
production data. The
data is retrieved
as the interface.
input data consist
from the InFusion
Lab results that are
related to a plant
mass flow data
from the InFusion
results are stored
are made available
mass balance error
in the InFusion
to the other PIM
events. The operator
and the output data
may include data
is available for the
values are available
with the help of an
from the InFusion
KPI calculations and
to the SAP system.
environment by a
the SAP interfacing.
The unit based mass
in the Logbook to
and energy balance
application is run
data from tags in
every hour to detect
By starting with an initial $PI template, the following configuration
the InFusion plant
model (including lab
model errors and to
information was required to provide full functionality:
sample data). It also
provide input data
acts as an electronic
for the complex wide
mass balance and
Figure 4: Derivation (tree) and field attributes
• Field Attributes
• Object Information
instructions, shift logs, shift handover etc.).
Oil movement within
The alarm and
Long range planning
monitoring or ‘Run
the refinery and
and medium/ short
application has been
term planning are
is aided by the TIS/
designed to have a
performed using LPs
in the InFusion
and the approved
environment. For all
and control systems.
to the PCS OPC
plan is broken down
simple spreadsheet that captures the design intent, H2 Consumption
plants and units and
servers as the DAHS
into daily production
in this case, with a logical flow of the formula to be used as the key
the ‘Running’ or
not support an OPC
performance indicator, followed by the inputs. The engineering units
‘Stopped’ status is
AE server, nor does
Targets are set for
InFusion have an
production based on
are then labelled below along with ancillary information such as
the process. The
OPC AE client. There
functional notes that allow the engineer to configure the point’s value in
number of starts and
tracking and other
is no integration
run time is stored
with the InFusion
the terms that the end user will want to see as output.
in the InFusion
be controlled as a
yields are balanced
key feature of the
from the launch pad
each time an object
PIM System suite of
in the PIM System
changes states to
the ‘Stopped’ status
The alarm and
The schedule is the
a downtime event
main focal point
is reported to the
is capable of
alarms and events
(against the plan).
• UDAs (User Defined Attributes) • Extensions A sample $PI design spreadsheet is shown in Table 2. This tool is a
The tags (instances in InFusion language) were populated into the shell structure of the InFusion site-specific environment of the galaxy, as
combined with process trend data. The data are retrieved from DAHS using OPC HDA on demand.
Table 1: Application components
The $PI instances select their input values from Exaquantum tags. These inputs are usually aggregated values (average and sum) over 24-hours. When the aggregation is unavailable from the DCS, it is handled by the InFusion System at the Historian level. Event tags and stored procedures were developed to submit this information to the running PI.
Figure 5: User Defined Attributes
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Plant Information Management System at Petro Rabigh
Table 2: Engineering design worksheet
shown in Figure 5. Most of the work involved dragging-and-dropping
Additional functionality can be found in the ‘Extensions’ tab (not
many of the redundant attributes. InFusion allows the designer to
illustrated here) that allows the engineer to drive the inheritance
replicate these redundant attributes by inheriting tag instances (such
relationships of inputs and outputs, customise the engineering units
as parent to child relationship). The attributes, shown as instances in
of measure, lock the linked sources of outputs and alarms and change
Figure 5, were pulled into the InFusion model using a *.csv file, saving
other variables for fully customised control.
data entry time and errors.
Scripting UDAs (User Defined Attributes) Finally, scripting capability enables the engineer to develop calculated Once the instances are set up, UDAs help to implement the full
functionality right into the development interface (see figure 7). Simple
functionality of InFusion. The UDA allows the designer to satisfy
Boolean scripts, logical expressions or complex arrays can be used to
process variables for the cost and quality requirements. Design and
drive the output and linked tags to yield desired results.
testing can be done concurrently by deploying whole sections of the Galaxy without interruption to production. Galaxy is a term InFusion
Scripts developed for Petro Rabigh PIs, made sure that engineering
uses to define the entire application. It encompasses the complete
units for the DCS value falls in line with the mandatory formula
ArchestrA system consisting of a single logical name space (defined by
requirements. In some cases, the conversion multiplier was used
the Galaxy Database) and a collection of platforms,
to factor the values from the DCS and in InFusion (such as unit of measure).
As the name implies, the UDA allows adding and customising parameters through the $PI configuration. The $PI acquires data from
The script executes the formula and then handles all possible
disparate sources and routes the data throughout the $PI system’s
exceptions such as a mathematical logic error that is encountered from
infrastructure. These parameters can be a variety of types: Boolean,
a division by zero. Additional parameters handled by scripting are
double, elapsed time, float, integer, string and time. For each UDA,
based on certain conditions (such as exceeding upper and lower limits
the engineer can specify an initial value and category. This is similar to
of a parameter). The script sends a message to the Operator LogBook
securing access to the UDA (such as read/write), with each $PI instance
applications for notification and alarming.
having two sets of UDAs – a set inherited from the parent template and a set of UDAs defined for the specific $PI.
But enough about the design aspects! Who were the people that pulled the design requirements together and carried out the mission of
designing and building the system? The people side of the project was at least as interesting as the technical aspects outlined above.
The systems engineer can extend UDA functionality by: adding input and/or output extensions, locking the linked sources of outputs and
8. Key to mission success – the people involved
alarms, historisation, customising the engineering units of measure per UDA and changing other variables for fully customised control.
Working on an international project can be an experience of a lifetime.
May/June 2012 | 53
“From an engineering work effort perspective, InFusion altered the track from exigent to lenient. The multi-disciplined environment helped our engineers contribute from across the globe. This increased efficiency and minimized cost while the centralized database ensures that maintenance effort and cost will be reduced. With the large number of points and the continuously changing requirements as we proceeded, the different system features made it possible to accommo-date bulk changes in minimum time. The InFusion Integration capability is humongous, there’s no single application we could not plug in, not a single requirement we missed. It was thrilling seeing this grow to what it is today.” Eva Hachem, Lead Engineer, Invensys Middle East FZE, June 2009
Figure 6: Scripts tab
The rewards are many but the challenges can be taxing. Assuming you can surmount the language barriers and navigate through cultural differences; you still must complete tasks and meet deadlines. Projects are inherently collections of divergent people with different needs and perceptions. Luckily, the ‘work of it’ (things to be completed) can draw people together toward a common end. Relationships get formed, people help each other and the job gets done. Having a workable location and supportive leadership will help keep things moving along and leave you with lasting work relationships while accomplishing more than you ever thought possible. The key is to open your mind to things that you do not know or understand and soak in the world. The project will keep you centred on the things that lead to success. A project of this magnitude required an eclectic mixture of people from across the globe. Once the project started, the Invensys project management team pulled together the resources required to get the job done.
The customer Being a joint venture with Sumitomo and conceiving a business driven Plant Information Management System in the early phase of construction, Petro Rabigh has been unique in taking a bold and challenging initiative to implement an integrated enterprise-wide system that is fully operational as the plants come on stream. They
54 | www.protocolmag.co.za
Invensys provides the most comprehensive portfolio of solutions—designed to measurably improve business performance and value in real time. Enabled by our industry and production expertise, and accelerated by an open software platform and partner ecosystem, our flexible approach perfectly blends automation and information technologies, services and expertise into highly effective solutions. Solutions that solve problems and optimise the profitability of operations—from single plant devices, to multi-plant assets and locations, up through global supply chains and enterprise business systems. Invensys offers the most holistic and cost effective way to optimise the business impact of your operation’s performance and overall profitability. We help improve the performance of your key resources (people, equipment, energy and materials) in real time—with dramatic, measurable results—using a collaborative and open approach.
Plant Information Management System at Petro Rabigh
Construction status as of July 2009:
The systems programming solutions provided the technical expertise
The start-up of the Company’s New Facilities was originally scheduled for the 4th quarter of 2008. However, start-up was delayed to the 1st quarter of 2009 due to the delay in the completion of construction work that was generally caused by the tight labour market and the shortage in skilled labour. The construction activities were substantially completed by the end of December and the Project is in its start-up and commissioning phase. The ethane and butane gas pipelines, from Yanbu to Rabigh, that provide the Company with its feedstock, are now fully operational. All process plants have now been completed and handed over to the Company’s operation team. Construction work force, which peaked at nearly 40,000, is now below 2,000. Start-up preparation activities are well under way and hydrocarbon has been introduced to several facilities as part of this exercise. At the time of writing this article all but the last polymer plants have been started up successfully.
customer’s screen and process engineering expertise came from the
PR 2008 - Annual Report to Board of Directors
construction level with much of the systems supplied by other
for the mass of code underlying the simple symbols showing up on the Invensys Development Centre, Pvt. in Hyderabad, India. Project management and additional systems development had contributions from Invensys locations in Houston, Texas and Foxboro, Massachusetts, USA. Much of the project was conducted remotely via network connections to optimise team efficiency and minimise travel costs. Clearly, this was an international effort in the true sense of the word.
In a project such as this, no man is an island and no company works in isolation and so, Invensys had help from other companies. This included competitors and consultants who worked in an open office environment where sharing information was of paramount importance. This was completed in deference to traditional sequestered development projects to quickly get the job done and with the collaboration of different technical experts. Even tasks of higher order of magnitude such as project management and technical specification definition was done with the help of non-Invensys partners. The project reflected the multi-contractor effort at the plant companies. Great synergy was realised by adding people and companies of varying origin so a process flow diagram could be built
were undaunted by the challenges posed by the lack of actual data to
into a working Operations Management System. No elaborate prizes
validate the solution while the complex was still under construction and
were given or needed - suffice it to say that their contributions were
were quite appreciative of the difficulties in commissioning the system
invaluable (see references).
under such circumstances, proving themselves to be a wise and well disciplined customer.
The project management team demanded excellence and set high
Pulling all this together is exactly what the InFusion Operations
expectations at every stage of the project. They exhibited technical
Management can do for very complex systems. The interactions of
competence and the spirit of cooperation throughout the project
people and technologies can make for either a very difficult or very
life cycle that proved invaluable in commissioning the solution in a
successful implementation; the degree of difficulty depends on
bringing the right tools and hands together.
This article describes the combination of technical challenges and personal efforts of a well-meshed team that contributed an enormous
Application engineers from the Invensys Middle East, Europe, India
effort to deliver a best-in-class integration of the large range of
and North American divisions accomplished the construction and
advanced systems that the customer demanded. Integration was the
development of the system. The project was managed with the help
key; No other model fitted the tall order for a profit-driven market that
from local professionals and managers with the mixture of people
required advanced applications that were made easy to deploy.
assigned to the project from various locations. The hosting location for this project was Invensys Systems N.V. (Baarn, The Netherlands) which specialises in designing, manufacturing, marketing and servicing instruments and systems for process management and control for the process industries. The senior technical lead insisted in bringing the resources to the Baarn hub to effectively launch and drive the project through to completion. Baarn also served as a host site for the Factory Acceptance Testing (FAT). Invensys offices in Dubai, UAE, became the next stop for the project team as development migrated toward commissioning.
May/June 2012 | 55
10. Glossary of terms and abbreviations
Term or acronym
Meaning or Petro Rabigh equivalent wording
The list below is by no means comprehensive but rather just a listing of
Data Acquisition And Historian System
people who contributed to both the project and this paper. Additional
Distributed Control System
Enterprise Control System
Enterprise Resource Planning
Functional Design Specification
High Density Polyethylene
The complete ArchestrA system consisting of a single logical name space
International Standard for the integration of enterprise and control systems
Company providing Combined Heat and Power services to all new plants at Rabigh (Independent Water, Steam and Power Provider)
Key Performance Indicator
Laboratory Information Management System
Liquid Petroleum Gas
Mono Ethylene Glycol
Manufacturing Execution System
Microsoft Structured Query Language database
Open Database Connectivity
OLE (Object Linking and Embedding) for Process Control
Process Control System
OSISoft Plant Information
Plant Information Management System
SAP Quality Management Inspection Data Interface
System Analysis and Program Development
Site Acceptance Test
Electric power company
User Defined Attribute
56 | www.protocolmag.co.za
contact information can be obtained through the Invensys Public Relations Department.
Contributing authors/reviewers: • Amol Bodhale, Process Engineer, Invensys • Eva Hachem, Lead Engineer, Invensys • Hans Otzen, Senior Engineer, ATOS Origin • John Hernandez, Managing Consultant, Invensys • Mhanna Awari, InFusion Engineer, Invensys • Yadukulatilakam Ramaswamy, Senior Director, Consulting Services, Invensys
Consulting subject-matter experts: • Rene Heijenberg, Invensys • Ryan Van Slooten, Invensys • Udo Zwart , Senior Consultant and Director of SUMMIT Holding B.V.
Company weblinks: • Invensys: iom.invensys.com • Petro Rabigh: www.petrorabigh.com
Australia’s QR National chooses Invensys Rail to cope with soaring mining freight needs
Australia’s QR National chooses Invensys Rail to cope with soaring mining freight needs If there is one objective common to all mining operators, it has to be
The project included:
their ability to increase their mining export capacity. • An extra loop and additional holding roads at the Port of Hay Point One of the largest rail infrastructure projects ever undertaken in the State of Queensland, Australia was recently completed for QR National – the largest rail freight/heavy haul operator in Australia. The objective of the $1.1 Billion project was to increase coal capacity
• Duplicated track and new bridge construction between the port and Pring Rail yard • Upgrading Pring Rail Yard with new holding roads and yard lighting
from a number of mine sites to port, to match the expansion of its
to allow for increased rolling stock needed to handle the anticipated
feeder Coal Terminal in Central Queensland, Australia.
growth in coal production and
The result was a doubling of throughput capacity from 25 million tons to a staggering 50 million tons per annum. Invensys Rail’s
• Track formation renewals, track slewing, bypass loops, crossovers and a new bridge between the yard and Bogie River.
scalable solution resolves its mining operators’ coal freight capacity requirements now and into the future with the platform for potential
A true end-to-end solution provider, Invensys Rail’s scope of works
expansions to more than 200 million tons.
included the design of a new and modified signalling infrastructure, the supply, assembly, installation, modification, upgrading, staging, testing
Invensys Rail’s close partnership with its customer allowed performance
and commissioning of the new and modified signalling system as well
improvements and innovation to flow easily between them which saw
as the installation and upgrading of five level crossings.
the 20-month project completed a month ahead of schedule and on budget, despite having to contend with numerous adverse natural
Infrastructure works included a second balloon loop at one location,
two new passing loops and two extended passing loops with new interlocks, new holding roads, duplicated track sections necessitating nine Westrace interlocking installations and additional hot bearing asset protection requirements. As the principle contractor, Invensys Rail delivered its project works with an impeccable safety record of zero lost time injuries in nearly 200,000 exposure hours worked. Invensys Rail, a division of the global technology company, Invensys plc, employs over 4,000 people and is operational in over 30 countries around the world delivering state-othe-art railway control and communication solutions.
To see what Invensys Rail can do for you, contact Mike le Plastrier at firstname.lastname@example.org or call him on 011 607 8269. For more information on Invensys Rail’s systems and capabilities, visit www.invensysrail.com/mining.
May/June 2012 | 57
Operational Performance Management - Focusing on the right aspects Introduction
accepted under current economic pressures and competition within manufacturing
Technology is defined as the sum total of
and processing. Poor decision making in
knowledge and information that society has
this environment erodes operating profit,
acquired concerning the use of resources
sustainability, predictability, quality and the
to produce goods and services. Technology
ability to comply with environmental and
affects the technical efficiency with which
resources are combined in production. An improvement in technology therefore
Operational variance impacts on many
means an increase in the technical efficiency
areas of a manufacturing business and
of production - more output with given
probably most visibly on profitability.
inputs or fewer inputs for a given output.
Significant performance variation is,
Technology is often embodied in capital
however, synonymous with limited or lack
goods but from an operational performance
of appropriate performance measurements.
management point of view, technology
The following case study illustrates the
also exists as human capital. Within the
production and manufacturing environment,
Dr. Kobus van der Merwe of Industrial Management Enhancement
performance i s a function of operational
(a) The implementation of appropriate
personnelâ€™s knowledge and experience
performance measurements provides a
applied across different production units and
platform for improved process management
Human capital exists in most organisations
(b) Delivering insight and understanding
as unstructured and undocumented
(training) of the production process
knowledge. Experiential knowledge
generates significant value.
is gained over time and the loss of experienced personnel pose a significant
This case study provided an accurate
long-term risk in the absence of programmes
definition of the opportunity and also
aimed at continued training, development
provided information allowing for
and capturing of validated knowledge.
progressive performance tracking and project risk management.
Experience-based learning consists of sequenced activities described as
observation, interpretation, choice (action implementation) and subsequent evaluation,
Revenue, contribution margin, cash flow
via a feedback mechanism which is the
and stock price are among the top financial
systemâ€™s response to the action. In the
performance metrics used to state an
absence of effective feedback mechanisms,
organisationâ€™s financial performance.
the experiential learning cycle is much
Performance measurements are structured
longer and / or knowledge becomes biased
and implemented to direct attention to
or inaccurate. The quality of decision-making
specific aspects of the business that may be
of concern. The complexity of performance management increases substantially
Poor decision making cannot be tolerated or
58 | www.protocolmag.co.za
for organisations that have process and
Operational Performance Management - Focusing on the right aspects
manufacturing plants as part of their
portfolio. These organisations require insight into production-related inefficiencies and
As illustrated in figure 1, substantial
how they will impact on strategic decisions
improvements were realised subsequent
and sustainability of the operation.
to the implementation of initial solutions.
About Industrial Management Enhancement
Information generated by the Operational
Experience has shown that most
Ideal operating conditions are characterised
Performance Management programme
production plants operate in an unstable
by higher energy efficiency, operating
assisted with the definition of initiatives
or high risk state for 60% or more of the
asset reliability, effective asset utilisation
and critical areas. Team learning, change
and adherence to quality / environmental
management, innovation, systemic thinking
standards – in general, higher efficiency. In
and reliable definition of the future state
Operational risk encompasses the
most cases, operating cost are reported as
all contributed towards the value that w as
potential loss due to the breakdown of
an aggregated value which, by implication,
controls. Breakdown of control results in
masks the impact of varying efficiency. Many
unpredictable and unstable production
operations have limited or no knowledge of
Improvements were realised through
processes. By implication, this condition
the periods during which their production
effective management of the production
results in an inability to meet production
processes operate in an ‘ideal’ state. Our
process. The latter was achieved by
research shows that most production
leveraging existing infrastructure and assets
processes operate in an ideal state less than
as well as people development. The total
IME delivers Operational Performance
40% of the time and that significant losses
operating profit increased subsequently by
Management solutions to the process
are directly attributable to this situation (it is
more than 10%. This project realised a better
and manufacturing industry. A structured
also confirmed in this case study).
than four-fold payback within the first year.
and proven methodology is utilised to
Insight into the time that production
For more information contact:
analyse and troubleshoot the process to
processes don’t operate in an ideal state
Dr. Kobus van der Merwe
quantify Operational Risks. Projects are
helps to quantify operational risk exposure.
Industrial Management Enhancement
characterised by high returns, a strong
A platform is therefore established to plan
Mobile: +27 (0)82 656 5601
emphasis on training and development,
and structure improvement initiatives that
and solutions facilitating asset sweating.
construct process status maps and to
will contribute best toward operational efficiency.
Application Environment From a strategic planning point of view, the client required insight into the installation’s ability to sustain high performance. This installation is utilised to produce different product grades, each with a unique chemical composition. An assessment was requested to quantitatively describe process conditions, quantify the time that the process operates under each condition and to establish solutions facilitating effective process management. A structured programme was followed to characterise different operating conditions and matching operational performance. Information generated by this project delivered insight into the relevant aspects to be addressed and helped to define solutions that led to pro-active process management (i.e. managing the production process to maximise the time in the ideal state).
Figure 1 – Impact of focusing on the right aspects (after providing relevant information)
May/June 2012 | 59
Are CIOs being caught napping? â€“ IT Governance and Process Automation Introduction networks, patches, databases as well as Traditionally Corporate IT and Industrial IT
backup and recovery procedures. An even
(Automation) have been the oil and water of
greater challenge has been the opening of
computer systems. Automation (and the IT
the factory black box to the ERP systems.
equipment used by Automation) has been
This has required more and more forced
the realm of the engineers and the increased
integration of the two worlds. So how will
focus on Corporate Governance has largely
this space evolve in the future? We attempt
gone unnoticed in this domain.
to describe some predictions below. Regardless, going forward, CIOs will have an
Simultaneously, IT technologies, processes
interesting time explaining to shareholders
and complexity have now become
and the board why IT equipment utilised
pervasive in Automation systems including
in Automation is not under their control,
virtualisation, anti-virus management,
governance and management.
John Coetzee â€“ Business Development Director, Aristotle Consulting (Pty) Ltd.
Figure 1: CobiT content diagram
60 | www.protocolmag.co.za
Are CIOs being caught napping? – IT Governance and Process Automation
nor feathered, but burying his head in the
Plan and Organise
sand). A major corporate incident, as a It is almost impossible to have automation
result of a failure in the technology platform
The Plan and Organise domain considers
systems without significant dependency
of automation, will eradicate all debate
the strategic direction to be applied to
on “IT technologies”. Examples of these
as to who is accountable and a task team
Acquisition and Implementation as well as
abound: networking is common to allow
will likely be established with a request to
to Delivery and Support. The elements we
information flow from shop floor control
drive IT governance processes rapidly into
consider mostly significant to management
devices to databases, visualisation systems
the automation systems layers. A strong
of Automation IT are:
and cross-process controls. It is also a
suggestion is that the CIO and Engineering
growing requirement for this information
proactively bridge this gap before an
to flow (in pseudo real-time) into business
incident forces them into actions that may
strategies should consider requirements
ERP and other transactional processing
result in red faces.
and direction of Automation IT and
systems. Applications run on servers and client PCs. Information is logged in
• Systems Strategy – Corporate IT
provide an integrated strategy for the
Is there a better way?
SQL databases and reported across the • Investment Plan – Automation IT should
enterprise. The list is long and growing
Simply put, it depends. A collaborative
model where IT technologies are governed
have a consistent forecasting investment
by central management procedures can
plan for the 3-5 year window. This plan
The “Corporate IT” environment is now
yield labour productivity and improved
should be integrated to the Corporate
dominated by integrated business and
reliability. Consideration needs to be given
IT plan to leverage scale and ensure no
governance processes. These are commonly
to maturity of Corporate, Automation
based on ITIL, CobiT, ISO 27001 and/or ISO
as well as the skills and personalities
31000. Requirements are also laid down
involved. Implementing collaboration here
by King III and Sarbanes-Oxley and are
is very definitely a challenging Change
planning human resources and integrated
particularly onerous on the CIO. The CIO,
Management problem. CobiT provides
career paths between the two functions
by specifically excluding the control and
a good point of departure from which to
provides many more options for
automation environment, is behaving like
analyse areas where common management
development and growth (and therefore
the metaphoric ostrich (neither flightless
can be achieved (figure 2).
motivation and skill) of employees in
• Human Resource Management – By
Figure 2 – Proposed focus areas for PCS vs IT Integration
May/June 2012 | 61
both functions. The opportunity for
• Ensure Continuous Service – Continuity
cross-function specialisation can yield new
planning is critical to ensure reliable
opportunities for value and optimisation.
and efficient service delivery. Shared knowledge between the two functional
• Risk Management – The risk management practices of Corporate IT
teams can improve integrity and completeness of these plans.
About Aristotle Consulting
have matured over the decades and with the likes of King III, become essential for
• Service Level Management – Typically,
Aristotle Consulting offers consulting and
good management. These practices can
Corporate IT is expert in managing
training services to the Manufacturing
readily be applied to Automation IT and
service level agreements (SLAs). Vendor
Industry. Training courses include: WCM
will bring an added level of risk mitigation
support to automation can be significantly
Goal Development, WCM 5S, WCM Service
above change management and backup
improved by the implementation of
Management, WCM Problem Solving, WCM
and recovery practices.
professional, measurable SLAs.
Value-stream mapping and workflow as well as Technical and Management Courses for
• Project Management – Both functions
Monitor and Evaluate
can benefit from sharing expertise
Service-Level Agreements, Automation Project Management, Management for C&A teams,
and quality assurance management
The Monitor and Evaluate domain is to
Maintenance Management, SQL Basics as well
of projects. Developing an integrated
ensure compliance with the strategic
as Intermediate and Business Statistics.
approach to project implementations
direction provided and to drive continuous
across both can provide significant
improvement. requirements. Detailed paper trails can
improvement in project success and the proactive rather than retrospective
• Performance Management – The
be developed and linked to the specific
alignment of IT and Automation
development of a balanced set of
equipment which can prove helpful in
performance targets and tracking
problem solving and analysis.
performance against each of these should
Acquire and Implement
be transparent across both functions.
These are just some of the areas where value
Visual management of these metrics will
and synergy can be pursued.
The Acquire and Implement domain is the
add to the awareness and drive action to
provisioning of solutions to be managed by
ensure compliance and rectification of
Delivery and Support.
Conclusion There are likely numerous additional
• Procurement Management –
• Governance Management –
areas where collaboration and integration
Centralising procurement can result in
Leadership, structures, roles and
between Corporate IT and Automation
better scale benefits as well as more
responsibilities and processes all
IT can be extracted by moving towards a
consistent adherence to hardware and
need to be defined, especially when
totally-integrated IT management solution. It
operating in a more tightly integrated
is recommended that organisations perform
management environment. Ensuring
a critical self-review and ensure that the most
single accountability is critical to ensure
value is extracted and greater alignment is
successful operation and delivery.
created between these two functions. It will
• Change Management – Coordination of changes in Automation and Corporate IT are becoming increasingly critical due to increasing data and application integration between the two functions.
become a competitive advantage for the
Other opportunities for synergy
The change control processes need
leaders and an anchor for the stragglers. It’s time for CIOs to stop napping and awaken to the possibilities!
to be carefully engineered to allow for
Corporate IT could learn a lesson from
an appropriate method of approving
manufacturing plant maintenance solutions
For more information contact:
emergency changes and also to ensure
and processes, particularly where a
that general change control is not too
philosophy of total productive maintenance
Business Development Director
bureaucratic or onerous.
has been adopted. Maintenance systems
Aristotle Consulting (Pty) Ltd
for plant equipment are often distinct to
Landline: +27 79 517 5261
the maintenance systems (if any exist) for
IT assets. Adoption of these systems for
Deliver and Support Deliver and Support ensures usability of
management of IT assets has been done at
solutions to the end customer. The skills
organisations with great success.
required by the two domains are likely to differ when it comes to software support,
Linking Document Management systems to
but hardware support can easily be common
maintenance systems allows for particular
testing of procedures and governance
62 | www.protocolmag.co.za
May/June 2012 | 63
Information dictionary Acronyms
American Standard Code for Information Interchange
Control OBjectives for Information and related Technology
Enterprise Manufacturing Intelligence
Enterprise Resource Planning
Food and Drug Administration
Field Device Technology
File Transfer Protocol
Integrated Development Environment (ArchestrA)
International Organisation for Standardisation
The American Standard Code for Information Interchange is a characterencoding scheme based on the ordering of the English alphabet. ASCII codes represent text in computers, communications equipment and other devices that use text. Most modern character-encoding schemes are based on ASCII, though they support many more characters than ASCII does.
Context The circumstances that form the setting for an item of information and without which, that information could be misinterpreted or not fully understood.
COBIT First released in 1996, COBIT is a framework created by ISACA (Information Systems Audit and Control Association) for information
Information Technology Infrastructure Library
Laboratory Information Management System
Overall Equipment Effectiveness
Manufacturing Execution Systems
Remote Terminal Unit
Relational Database Management System
Supervisory Control and Data Acquisition
Statistical Process Control
Structured Query Language
Transmission Control Protocol
Transmission Control Protocol / Internet Protocol
Telephony Application Programming Interface
technology (IT) management and IT Governance. It is a supporting toolset that allows managers to bridge the gap between control requirements, technical issues and business risks.
Data Data are typically the results of measurements and can be the basis of graphs, images, or observations of a set of variables. Data are often viewed as the lowest level of abstraction from which information and then knowledge are derived. Raw (unprocessed) data refers to a collection of numbers, characters, images or other outputs from devices that collect information to convert physical quantities into symbols.
Database A database is an organised collection of data for one or more purposes, usually in digital form. The data are typically organised to model relevant aspects of reality (for example, the number of on-off valve operations in a plant), in a way that supports processes requiring this information
Aggregate data - Data combined from several measurements
(for example, determining the supplier whose valves tend to fail more
ArchestrA â€“ Released in 2003, ArchestrAâ„˘ technology is a
Business Intelligence (BI)
frequently than others).
comprehensive plant automation and information architecture designed from the outset to extend the life of legacy systems by leveraging the
This mainly refers to computer-based techniques used in identifying,
latest software technologies like Microsoft.NET. Offerings built upon this
extracting and analysing business data, such as sales revenue by
architecture empower decision-makers to achieve their business goals,
products and/or departments, or by associated costs and incomes. BI
without abandoning prior investments in automation systems, production
technologies provide historical, current and predictive views of business
processes or intellectual property. In the ArchestrA environment, software
operations. Common functions of business intelligence technologies are
applications can be rapidly assembled rather than programmed. New
reporting, online analytical processing, analytics, data mining, process
applications can also be created simply through the reassembly of
mining, business performance management, benchmarking, text mining
and predictive analytics.
64 | www.protocolmag.co.za
implement controls, including audits, system validations, audit trails, electronic signatures, and documentation for software and systems
The bringing together of various interlinked items of information in order
involved in processing electronic data that are (a) required to be
to get a more holistic understanding of the matter under investigation.
maintained by the FDA predicate rules or (b) used to demonstrate compliance to a predicate rule. A predicate rule is any requirement set
forth in the Federal Food, Drug and Cosmetic Act, the Public Health Service Act, or any FDA regulation other than Part 11.
In terms of the field of communication, this means to broadcast a message to the public without direct feedback from the audience.
File Transfer Protocol (FTP)
Enterprise Manufacturing Intelligence (EMI)
This is a standard network protocol used to transfer files from one host to another host over a TCP-based network, such as the Internet. FTP is
Iis a term which applies to software used to bring a corporation’s
built on a client-server architecture and utilises separate control and data
manufacturing-related data together from many sources for the purposes
connections between the client and server. FTP users may authenticate
of reporting, analysis, visual summaries and passing data between
themselves using a clear-text sign-in protocol but can connect
enterprise-level and plant-floor systems. As data is combined from
anonymously if the server is configured to allow it.
multiple sources, it can be given a new structure or context that will help users find what they need regardless of where it came from. The primary
goal is to turn large amounts of manufacturing data into real knowledge and drive business results based on that knowledge.
Galaxy is the term used to describe the complete ArchestrA system database − consisting of a single logical name space (defined by the
Enterprise Resource Planning (ERP)
Galaxy database) and a collection of Platform objects, Engine objects, and other Application objects. The Galaxy database is a relational
ERP integrates internal and external management information across
database containing all persistent configuration information like object
an entire organisation, embracing finance/accounting, manufacturing,
templates, instances, security, etc.
sales and service, customer relationship management, etc. ERP systems automate this activity with an integrated software application. Its purpose
is to facilitate the flow of information between all business functions inside the boundaries of the organisation and manage the connections
A device that logs all real-time values and events in a production facility
to outside stakeholders.
and which makes these data available for analysis and reporting.
Fieldbus This is the name of a family of industrial computer network protocols used for real-time distributed control, now standardised as IEC 61158. A complex automated industrial system — such as manufacturing assembly line — usually needs an organised hierarchy of controller systems to function. In this hierarchy there is usually a Human Machine Interface (HMI) at the top, where an operator can monitor or operate the system. This is typically linked to a middle layer of programmable logic controllers (PLCs) via a non-time-critical communications system (e.g. Ethernet). At the bottom of the control chain is the fieldbus that links the PLCs to the field devices that actually do the work, such as sensors, actuators, electric motors, console lights, switches, valves and contactors.
FDA 21 CFR Part 11
InTouch HMI screen showing a user-defined interface for access to OEE information in real-time
Title 21 CFR Part 11 of the Code of Federal Regulations deals with the Food and Drug Administration (FDA) guidelines on electronic records
Human-Machine Interface (HMI)
and electronic signatures in the United States. Part 11, as it is commonly called, defines the criteria under which electronic records and electronic
An evolution of the more gender-specific MMI (Man-Machine Interface).
signatures are considered to be trustworthy, reliable and equivalent to
HMIs run on PCs or thin clients that are connected to Programmable
paper records (Title 21 CFR Part 11 Section 11.1 (a)).
Logic Controllers (PLCs) which are physically connected to sensors and actuators in the machinery of the shop floor. The combination of HMI and
Practically speaking, Part 11 requires drug makers, medical device
PLC is referred to as a SCADA system.
manufacturers, biotech companies, biologics developers, CROs, and other FDA-regulated industries, with some specific exceptions, to
An HMI is a graphical way of allowing operators to interact with real-time
May/June 2012 | 65
production processes by presenting them with monitoring information
The King Report on Corporate Governance has been cited as “the
such as the state of the process parameters, alarms, etc. and also
most effective summary of the best international practices in corporate
providing a way to control the process via the PLC. HMIs like InTouch can
be linked to other applications such as Asset Management to provide overlaid maintenance information and procedures either locally or
Laboratory Information Management System (LIMS)
remotely through applications such as Wonderware’s IntelaTrac. HMIs can also show real-time trends through analytical applications such as
This is a software-based laboratory and information management system
Wonderware’s Historian Client (previously known as ActiveFactory). HMI
that offers a set of key features that support a modern laboratory’s
information can be viewed remotely through the use of solutions such as
operations. Those key features include — but are not limited to —
workflow and data tracking support, flexible architecture, and smart data exchange interfaces, which fully “support its use in regulated
environments”. The features and uses of a LIMS have evolved over the years from simple sample tracking to an enterprise resource planning
Fact or knowledge provided or learned and that can be acted upon and
tool that manages multiple aspects of laboratory informatics.
which is derived from raw data. This provides the first level of actions derived from the correct aggregation of data.
Manufacturing Execution Systems (MES)
Information Technology (IT)
MES provides the bidirectional link between business and production functions by providing real-time and near-real-time information about the
The computer, telecommunication, network and other technologies
status of production, maintenance, quality and inventory.
necessary to gather, store, collate and disseminate information.
Modbus Information Technology Infrastructure Library (ITIL) Modbus is a serial communications protocol published by Modicon This is a set of practices for IT service management (ITSM) that focuses
in 1979 for use with its programmable logic controllers (PLCs).
on aligning IT services with the needs of business. In its current form
Simple and robust, it has since become one of the de facto standard
(known as ITILv3 and ITIL 2011 edition), ITIL is published in a series of five
communications protocols in the industry and it is now amongst the most
core publications, each of which covers an ITSM lifecycle stage. ITILv3
commonly available means of connecting industrial electronic devices.
underpins ISO/IEC 20000 (previously BS15000), the International Service Management Standard for IT service management, although differences
between the two frameworks do exist. This is used in serial communication and makes use of a compact, binary ITIL describes procedures, tasks and checklists that are not organization-
representation of the data for protocol communication. The RTU format
specific, used by an organization for establishing a minimum level of
follows the commands/data with a cyclic redundancy check checksum as
competency. It allows the organization to establish a baseline from
an error check mechanism to ensure the reliability of data. Modbus RTU
which it can plan, implement, and measure. It is used to demonstrate
is the most common implementation available for Modbus. A Modbus
compliance and to measure improvement.
RTU message must be transmitted continuously without inter-character hesitations. Modbus messages are framed (separated) by idle (silent)
The ability to gain and apply knowledge and skills and to use original
Modbus TCP/IP or Modbus TCP
thinking to address the task at hand. This is a Modbus variant used for communications over TCP/IP networks,
International Organisation for Standardisation
connecting over port 502. It does not require a checksum calculation as lower layers already provide checksum protection.
Widely known as ISO, this is an international standard-setting body composed of representatives from various national standards organisations. Founded on February 23, 1947, the organisation
Overall Equipment Effectiveness (OEE)
promulgates worldwide proprietary, industrial and commercial standards. It has its headquarters in Geneva, Switzerland.
This is a measurement (the product of Availability, Performance
and Quality) which evaluates and indicates how effectively a
The King Report on Corporate Governance is a ground-breaking code
manufacturing operation is utilised.
of corporate governance in South Africa issued by the King Committee
The results are stated in a generic
on Corporate Governance. Three reports were issued in 1994 (King I),
form which allows comparison
2002 (King II) and 2009 (King III). Compliance with the King Reports is a
between manufacturing units
requirement for companies listed on the Johannesburg Stock Exchange.
in differing industries. It is not
66 | www.protocolmag.co.za
however an absolute measure and is best used to identify the scope for
usage term varies with the application area generally.
process performance improvement and how to get the improvement. If, for example, the cycle time is reduced, the OEE can also reduce, even
though more product is produced for less resource. Another example is if one enterprise serves a high volume, low variety market and another
The Sarbanes–Oxley Act of 2002, also known as the ‘Public Company
enterprise serves a low volume, high variety market. More changeovers
Accounting Reform and Investor Protection Act’ (in the Senate) and
(set-ups) will lower the OEE in comparison, but if the product is sold at a
‘Corporate and Auditing Accountability and Responsibility Act’ (in the
premium, there could be more margin with a lower OEE.
House) and more commonly called Sarbanes–Oxley, Sarbox or SOX, is a United States federal law which sets new or enhanced standards for
all U.S. public company boards, management and public accounting firms. It is named after sponsors U.S. Senator Paul Sarbanes and U.S.
(1) A process typically describes the act of taking something through an
Representative Michael G. Oxley.
established and usually routine set of procedures to convert it from one form to another such as in manufacturing where aluminium is turned into
aircraft or processing paperwork to grant a mortgage loan, or converting computer data from one form to another. A process involves steps and
Supervisory Control and Data Acquisition. A system that is comprised
decisions in the way work is accomplished. A process monitors and
of one or more Programmable Logic Controllers (PLCs) as well as one
controls workflows to make sure that each step in the workflow (sub-
or more visualisation and control facilities (HMI) to oversee and control
process) conforms to set performance criteria. Depending on conditions,
real-time production processes.
process objectives may change, leading to a change in their operational requirements and performance criteria. This will result in a new or
Statistical Process Control (SPC)
modified process to meet the new objectives. Because of the “feedback, learn, redesign” loop, processes tend to be largely self-correcting (e.g.
SPC is the application of statistical methods to the monitoring and
the process of evolution).
control of a process to ensure that it operates at its full potential to produce as much conforming product as possible with the least possible
(2) A process is a series of controlled and measurable actions that
waste. SPC can be applied to any process with a measurable output. Key
involves feedback, learning mechanisms and contingency plans to
tools in SPC are control charts, a focus on continuous improvement and
transform energy and / or matter from one form into another (e.g. a
manufacturing process transforms raw materials into finished goods. A sales process transforms prospects into customers.)
Structured Query Language (SQL)
Programmable Access Controller (PAC)
SQL is a programming language designed for managing data in relational Database Management Systems (RDBMS).
A high-performance automation controller and I/O subsystem that marries high performance, reliability and high I/O density with costeffective redundancy options. The process modules and I/O system form the basis of a complete distributed control and recording environmen t capable of continuous analogue, logic and sequential control combined with secure data recording at the point of measurement. This shows several of the SQL language elements that compose a single
Relational Database Management System (RDBMS)
This is a database management system that is based on the relational
Telephony Application Programming Interface (TAPI)
model as introduced by E. F. Codd. Most popular databases currently in use are based on the relational database model. A short definition
This is a Microsoft Windows API, which provides computer telephony
of an RDBMS is: a DBMS in which data are stored in tables and the
integration and enables PCs running Microsoft Windows to use
relationships among the data are also stored in tables. The data can
telephone services. Different versions of TAPI are available on different
be accessed or reassembled in many different ways without having to
versions of Windows. TAPI allows applications to control telephony
change the table forms.
functions between a computer and telephone network for data, fax, and voice calls. It includes basic functions, such as dialling, answering,
Remote Terminal Unit (RTU)
and hanging up a call. It also supports supplementary functions, such as hold, transfer, conference, and Call Park found in PBX, ISDN, and other
This is a microprocessor-controlled electronic device that interfaces
objects in the physical world to a distributed control system or SCADA (Supervisory Control and Data Acquisition system) by transmitting
Acknowledgements: Many of the above definitions are sourced from
telemetry data to the system and/or altering the state of connected
objects based on control messages received from the system. Another term that may be used for RTU is remote telemetry unit, the common
May/June 2012 | 67
Report-back From the 15th to 18th April, Sun City was host to Invensys Operations Managementâ€™s annual User Conference as well as a record-breaking audience of over 400 local and international industry professionals. X-CHANGE has a justly-earned reputation as the largest and longestrunning conference of its type in South Africa and this 20th anniversary event was no exception. Notably, this was the first year that X-CHANGE represented the full range of products and solutions from Invensys Operations Management.
68 | www.protocolmag.co.za
X-Change 2012 Report-back
“When a variable is constant, you don’t have to control it.”
There isn’t enough room to document the full extent of the information shared by our four brilliant speakers but what follows is the gist of what
objective, highly-constrained optimisation problem “and we’ve never
they had to say:
figured out a way to solve those but if we can empower operators with the exact information they need in the timeframe they need it, they
Dr Peter G. Martin, Vice President
can solve the problem. How? We don’t know. What we do know is
Strategic Ventures, Invensys
that if engineers and IT people can collaborate on solving a business
Operations Management, talked
problem, the 100% ROI on such a project is about six weeks. CFOs
about minimising time to experience
can’t get a better deal and will soon recognise that you (the delegates) are the best investment your companies can make.”
and maximising performance. In its goal to be the innovator of industry,
Dr Peter G Martin
Invensys Operations Management
In short, operations excellence consists of four components:
has maintained a steady growth and achieved approximately a 4% growth in orders and 21% increase in revenue over the last year. “You (the delegates to this conference) need to know that you have a
• Control excellence – This includes plant floor AND business control with the objective of real-time profit control.
partner that is financially strong but more important than that, you also have a partner that is innovative,” said Dr Martin, showing the many
• Asset excellence – Asset performance control bearing in mind the
awards Invensys has achieved in this area as well as the nomination for
relationship between asset utilisation and availability. Executives
Microsoft Industry Software Partner of the Year.
consider assets to not only include equipment but people, raw material, energy and product as well.
In the largest survey ever conducted world-wide in industry, the majority of over 2000 executives said that their most valuable assets were talent,
• People excellence – As an example, operators have to make 150
information and the plant floor. Of the many factors that affected their
times more decisions than CEOs – the correctness of these decisions
businesses, Dr Martin expanded on three:
is based on the expertise of the people concerned and the quality of information they are provided.
• Downsizing – Over the last twenty years, this has most affected maintenance, operations, engineering and IT and the general consensus is that it’s gone too far. There are no longer enough
• Safety excellence – This is about safety initiatives that can measure risk and that are profitable because they ensure ongoing production.
people to do the jobs that have to be done. The result is that the industry has to change its mindset from downsizing to empowerment
To put all this together and bridge the
in order to retain valuable talent.
gap between operational and business systems, Invensys has introduced
• Profitability control – Up until now, the focus has been on process
the Enterprise Control System
control and efficiency control. This is no longer good enough. Today
called InFusion. The result is greatly
the focus must be on profitability control because the business of
improved operational excellence and
industry has changed from highly transactional to real time.
• Transactional to real-time business – A number of years ago, the
Tim Sowell, Vice President Solution/
price of electricity (in the US) was regarded as constant so much so
Product Strategy and Grant LeSueur,
that customers had year-on-year contracts with their energy suppliers
Director Product Management,
and so energy consumption didn’t have to be controlled because
Invensys Operations Management,
it was constant – “When a variable is constant, you don’t have to
spoke about Invensys’ vision and
control it.” But when deregulation was introduced, suddenly there
was competition. “In the United States today, the price of electricity changes every fifteen minutes and this started to affect every other
commodity that was energy-intensive. The price of copper, for example, changes three to four times a minute.”
The trend for the evolving industrial
And so the business of industry has changed from stable and
operational landscape is to focus
transactional to real-time. While executives believe this to be a chaos
on agility and empowerment. This
problem, it’s simply a control problem and one that the real-time
is happening at a time of transition
world of process control deals with routinely.
from a relatively aged workforce to a younger one with a different reality.
There are few variables that contribute to business profitability and they
Previously, people would stay in their
include production value, energy and materials as well as the safety of
jobs for five years or more but this
people, the plant and the environment. But this represents a multiple
is no longer the case. So, one of the
May/June 2012 | 69
challenges is to get people productive and knowledgeable in the space
That means that we don’t replace but align the existing applications,
of one or two years.
assets and systems and make them work together as if they were unified,” says Sowell. “Interestingly, Invensys Operations Management
Another challenge involves coping with the evolving real-time digital
has realigned itself to its own Enterprise Control Systems philosophy by
world where information and collaboration can be sourced from
aligning its solution offerings to that structure.”
anywhere in the world and collated with meaningful context before decisions are made – once again, anywhere in the world. They showed how the aim of current and future solution initiatives was to address improved operational control and decision support and to reduce the time-to-experience and time-to-performance of operational
“That means that we don’t replace but align the existing applications, assets and systems and make them work together as if they were unified,”
personnel. A second trend is that of addressing the following critical project
New releases and concepts
opportunities: All current and future releases focus on the simplification and • Network asset management - This involves measuring the
unification of resources as well as improved decision support, scalability
performance of all assets which may be at different plants all built by
and fault tolerance. There simply isn’t enough room in this article to
different people, in a consistent manner in order to compare apples
list what’s coming down the pipeline to support Invensys’ Enterprise
Control Systems concept but here are a few examples:
• Managing multiple assets as part of a supply chain – Assets are not isolated entities but collaborative components in a supply chain
• The implementation of a high-security communications bus structure between variously-sized System Platform implementations.
and that’s the way they should be perceived and managed. • The release of a Historian that will cope with a tag count ranging • Flexible operational team coordination – With available technology, the operational team takes on a new and global
from 125 to more than 400 000 as well as the simultaneous operation of two Historians.
collaborative dimension with the sourcing of knowledge from anywhere and at any time.
• A new ArchestrA service bus to enable secure inter-Galaxy communications.
• Standardised operational control loops – With this in place, it would eliminate the inconsistencies of how operations are executed
• Quality Management in MES 2012
and provide a baseline for measurement and improvement. • Model-driven operations management to provide a unified approach These and other industry trends dictate the way forward for the
to model-driven (embedded) operations execution.
development of Invensys Operations Management solutions. “One of the key factors is that we must provide unification through federation.
70 | www.protocolmag.co.za
• Empower operators to contribute to operational innovation through
X-Change 2012 Report-back
on-line training and simulations (virtual reality), not as an add-on but
somewhere for something,” says Baumhardt. “So, whether you know
embedded within products.
it or not, you already live in the cloud because you don’t care where something is stored or where it comes from – nor does it matter.”
• Empower roaming workers wherever they may be through Enterprise Manufacturing Intelligence on tablets and smart phones. This
But it does matter to some at the strategic and security levels and that’s
will lead to effective task management, planned inspections and
why provision has been made for private and public clouds. According
to Baumhardt, virtualisation and cloud computing are critical to the future because of the cost savings and information access benefits that
• Major release of Information Server that will allow for the collation and contextualisation of data from multiple sources
can be realised from these technologies which combine computing and telecommunications in highly beneficial ways such as guiding people through crisis situations. “Already, manufacturing and mining
• Extending the capabilities of the ArchestrA-based System Platform
companies are adding bandwidth to their production centres where
to improve flexibility and the lifetime of implementations to the
they create wealth instead of their business centres where they spend
• Evolving the multi-systems environment through multi-site runtime
Clem Sunter, legendary futurist,
systems, enterprise-wide standards management and the ability to
strategist and visionary, gave a
handle large integrated and configured systems.
stunning talk on the identification of factors that could influence the future
To summarise, future developments will focus on enabling operational
outcome of given scenarios. But more
excellence and unifying enterprises through facilitating workforce
than that, the actual early detection
collaboration and contribution by using solutions that add value
of these factors or flags pointed to a
because they are designed to address the broader business landscape.
major terrorist attack against the U.S. (see the letter sent to President Bush),
Fred Baumhardt, Head of Specialist
the current dire global economic
Team Unit and CTO, Microsoft SA,
situation and a number of other major
made a presentation that looked at the
political and economic possibilities.
future of technology and infrastructure. We cannot hope to do Mr. Sunter’s presentation justice here and urge In his book Technology of the future,
you to visit the web site: www.mindofafox.com where you will discover
English physicist and science fiction
fascinating facts about the past and even more interesting information
author Arthur C. Clarke stated that
about the world and South Africa beyond 1912.
“The only way to discover the limits of There you will find why the agility of the fox mindset is infinitely more
the possible is to go beyond them into
preferable than the doggedness of the hedgehog mindset that will do
the impossible.” Fred Baumhardt
anything to justify its viewpoint which it imposes on everyone. You’ll
At the human interface, information
be surprised at what politicians and CEOs with such a mindset have to
access and application selection side of things, the video shown at the
answer for – because they simply won’t listen.
conference seemed to do just that although most of the technology depicted exists already (affordable 3D desktop projections, on the
It’s all well written, easy and enjoyable to read and an eye-opener like
other hand, are probably at least ten years away).
It’s indisputable that what we can do with technology has grown as a
result of our ability to interact with them. For example, trying to do on-line banking with a DOS green screen and a command line interface
45 presentations covered a wide range of topics ranging from
can be challenging to say the least whereas all the complexity goes
technical to strategic while addressing the evolving and increasingly
away with a Graphical User Interface (GUI) and a mouse.
sophisticated and complex information needs of operational and business management at all levels of the enterprise.
The next move is towards the Natural User Interface (NUI) which will make technology a lot more natural and logical. For example, a unique
PIN was meant to identify a credit card holder as its legitimate owner. But this can be a flimsy security measure which can now be replaced
Invensys Operations Management is the first industrial automation
with any combination of RFID, face, iris and voice recognition (the last
provider to be certified for high availability, disaster recovery and fault
three being natural “PINs”).
tolerance in supervisory control applications through the leveraging of virtualisation technology. Historically, high-availability and disaster-
With the evolution of simpler access to computing environments, data
recovery solutions in supervisory control systems were expensive to
centres have also had to evolve to keep up with functional demands.
implement, not only because of hardware and software costs, but also
“Today, personal and other systems are next to useless if they can’t go
because of additional administrative burdens. Virtualisation and cloud
May/June 2012 | 71
computing go a long way to overcome these problems and Invensys Wonderware solutions now support both these technologies.
• Dynamic simulation and operator training simulator solutions for the minerals, metals and mining industries – Simulation saves colossal amounts of money, improves safety and prepares operators
SmartGlance cloud-based mobile reporting is becoming a must for
for the unexpected – especially when it’s as real as this!
the manager on the go while ArchestrA-based System Platform 2012, Historian 2012 and InTouch 2012 not only support virtualisation but
• Virtualisation for Wonderware: Soon to be an IT MUST have -
also now feature an impressive array of enhancements ranging from
How to create High Availability and Disaster Recovery solutions using
Enterprise Control and Process Analysis (System Platform) to new
virtualisation and using the new technologies available.
reporting functions (Historian) and strengthened security, increased operator and engineering productivity and efficiency as well as support
for the latest remote desktop services and virtualisation technologies from Microsoft (InTouch).
Invensys Wonderware’s ecosystem partners have always brought a level of added value that has made the difference between simply
Another development is Wonderware MES 2012’s new features which
having a solution and using it to its best advantage. Managing change
allow it to be used for quality and asset performance management
and disaster recovery (AutoSave for System Platform from MDT
while an increasing number of end-users are starting to realise the
Software), improving connectivity and network diagnosis (Software
incredible power of centralised and contextualised information
Toolbox), implementing thin client architecture (ACP ThinManager),
available through Wonderware Enterprise Manufacturing Intelligence.
providing quick and informative reports (Ocean Data Systems), easy production planning (Preactor), electronic logbooks to minimise risk
Also on the agenda were ArchestrA Workflow, which guides and
and downtime during shift changes (St. James Software) as well as
monitors human-level processes and Corporate Energy Management
improved plant safety, alarming and data security are all part of a tried
which transforms energy data of all types into operational information.
and proven range of professional solutions that integrate fully with Invensys Wonderware solutions. Don’t waste money on expensive
experimentation. Call in these professionals who have been there, done that and aptly demonstrated how they can prevent customers from
Some of the solutions presented included:
repeatedly reinventing an expensive wheel.
• AutoSave for System Platform – The world’s most popular change
Invensys Operations Management
management and disaster recovery solution is tightly integrated with System Platform to provide automatic and systematic backup of PLC
An entire presentation stream was dedicated to showcasing the
code, objects, graphics and templates.
• Mobile Solutions – With the advent of smart phones, tablets and
Foxboro offers clients process automation and control solutions to
handheld industrial computers, information is available on tap
meet the needs of virtually any enterprise in the process industries –
anywhere and in the most meaningful format
from stand-alone processes that need basic, reliable functionality, to complex integrated plants that control critical or hazardous operations.
• Invensys Sentinel Services - This new service from Invensys
Various presentations focused on the latest Foxboro I/A series DCS
Wonderware involves the remote 24X7monitoring of the health of
and its exciting future, the Programmable Automation Controller (a
customers’ Wonderware assets and warning of issues before they
powerful DCS in a PLC package) as well as an introduction to the
become a problem. Surely a no-brainer if optimal production is high
Foxboro Measurement and Instrumentation range of products which
on your agenda.
have almost become a global standard.
• Wonderware Software Asset Manager - This is an
An introduction to GeoSCADA hardware and software solutions
application designed to help customers manage their inventory
– This presentation was about the company strategy and rollout of
of Wonderware licences and software updates
SCADA products for the Invensys Operations Management portfolio. A great presentation for all involved in utilities and power.
• Advanced alarm management – Seeing the wood for the trees and setting priorities so that operators as well as all responsible
Triconex provides safety shutdown and critical control systems
personnel can respond more effectively.
that provide high-value solutions for critical control and safety applications including emergency shutdown as well as burner, fire
• Value engineering for production plants – Dr Peter G Martin showed how to extract maximum value from plant operations.
and gas and turbo-machinery control and protection. Triconex has been acknowledged as the world leader for more than 10 consecutive years and this presentation was an introduction to its world-leading
• SimSci-Esscor: Integrated process simulation, optimisation,
triple redundancy systems
training and advanced process control - This presentation showed how process simulation can help to improve the plant design process
Eurotherm was introduced to delegates as a leading global supplier
and plant control as well as operator training.
of control, measurement and data recording solutions and services to industrial and process markets. Eurotherm’s product range includes
72 | www.protocolmag.co.za
X-Change 2012 Report-back
distributed process automation systems and machine control
wasted energy while instilling a culture of efficiency.
incorporating single and multi loop control, operator displays, data management and graphic recorders, power control and signal
With the volumes that SAB handles, increasing packaging line
efficiency is high on the agenda of cost reduction and this was achieved using Wonderware solutions which also helped TSB Sugar migrate
Vertical Industry and end-user applications
from its legacy control system to newer technology.
14 industry-specific presentations showed how end-users and their
Regarding utilities, Eskom’s Koeberg Nuclear Power Plant
system integrators successfully implemented Invensys solutions.
implemented a remote notification system that provides key decision makers with up-to-date plant status information within their specific
On the metals and mining front, ArcelorMittal and Lonmin are
areas of expertise – wherever they may be.
both migrating their legacy control systems to the ArchestrA-based Invensys Wonderware System Platform and Lonmin also implemented
a fingerprint identification solution to secure access to InTouch applications.
22 hardware and software solution vendors from across Southern Africa and beyond demonstrated their real solutions to real problems.
Debswana Diamond Mining Company has completed a data mining exercise to consolidate all critical plant equipment information for
Invensys solutions alone may not be able to fix the problem. They may
Debswana mines into a single, user-friendly, easily-manageable and
require the expert implementation of professional system integrators
high-availability system while Exxaro Coal implemented a System
who are keenly knowledgeable of the problems their end-users are
Platform-based quality monitoring system to replace a legacy solution
facing. And then there are the complementary hardware and software
and Southgold Exploration is making use of an extensive suite of
solutions required to provide end-users the cost-effective value and
Wonderware solutions for its Great Basin Gold site
customised solutions they’re loo king for. This is the world of Invensys Ecosystem Partners who chose X-CHANGE 2012 to showcase their
Developments in the food and beverage industry include Nestlé’s
professional solutions. After all, they’re mostly responsible for the
Harrismith-based infant formula factory converting its continuous
information sourcing, processing and delivery aspect of most mining
mixing plant to batch processing mode (with results that surpassed
and manufacturing organisations.
product efficiency and accuracy expectations) and Entyce Beverages successfully completing a shop floor to top floor enterprise integration exercise. Mindful of escalating energy costs, Pastas Gallo and Conco (also known as Coca Cola Swaziland) implemented Wonderware’s Corporate Energy Management solution which highlighted the roots of
May/June 2012 | 73
Awards System integrator awards • Top SI: Control Systems Integration who also achieved “Invensys Endorsed System Integrator” status • Runner-up: Advansys • 2nd runner-up: Bytes Systems Integration • 3rd Runner-up: Iritron Casper Naude of Nestlé (2nd from right) and Juan le Roux of • 4th runner-up: Systems Anywhere
Convenient Software Solutions (left) receive the Best SCADA / HMI Implementation award from Tim Sowell and Deon van Aardt.
(From the right) Dries van Schalkwyk, Samantha Rabe, Tinus Botes
Wiseman Magagula of Conco (centre), Andre Vuilleumier (2nd from
and Jaco Malan (2nd from left) of Control Systems Integration
left) and Gordon Schoombie (2nd from right) of Systems Anywhere
receive the Top System Integrator award from Deon Barnard (left),
receive the Best EMI Implementation award.
and Fabrizio Orlando.
Invensys Operations Management Open awards • The Best SCADA / HMI Implementation award went to Nestlé and system integrator Convenient Software Solutions for the conversion of the continuous mi xing plant to batch processing mode at Nestlé’s infant formula factory in Harrismith. • The Best EMI Implementation award went to Coca Cola Swaziland (Conco) and system integrator Systems Anywhere for the implementation of a Corporate Energy Management system which resulted in excellent results for the company. • The Best MES Implementation award went to TSB Sugar and
Piet van Tonder of TSB Sugar (2nd from right) and Samantha
system integrator Control Systems Integration for the DCS migration
Rabe of Control Systems Integration receive the Best MES
project at TSB Sugar’s Komati mill.
• The Best EI Implementation award went to Southgold Exploration and system integrator Systems Anywhere for the extensive enterprise integration project at Southgold’s Great Basin Gold greenfield site.
74 | www.protocolmag.co.za
X-Change 2012 Report-back
International award Eskom and system integrator Bytes Systems Integration won the Invensys Operations Management Open 2011 Environment and Safety award for the implementation of an emission monitoring system at Eskom’s power stations. The installation monitors stack emissions and helps Eskom stay within legal limits while minimising the impact on the environment and helping to ensure continuity of supply.
Media partner South African Instrumentation and Control magazine (Technews Publishing (Pty) Ltd.) Mdu Mthethwa of Southgold’s Great Basin Gold site (2nd from right) and Andre Vuilleumier of Systems Anywhere accept the Best
EI Implementation award. An event like X-CHANGE takes more than six months to plan and
organise. From the invitation of international guests and call for presentations to venue logistics and awareness campaigns, this is no
The award for the most innovative use of Invensys Wonderware
casual event and Wonderware Southern Africa would like to thank
solutions went to ICS Automation for their implementation of
everyone who contributed towards making X-CHANGE 2012 the
Wonderware Enterprise Integration at Entyce Beverages.
success it deserved to be on this, the 20th anniversary of the longest running and most successful conference of its type on the continent.
Conclusion Hardware, software and turnkey solutions are only effective to the degree that they are accepted, implemented and proved to deliver their intended results. And that’s where end-users come in. Looking at the end-user presentations alone, it seems that migration from legacy DCS and other control systems is high on the agenda of forward-looking companies who realise that control systems, far from being isolated “black boxes” in the bowels of their organisations, are vital to the enterprise information delivery chain and need to be as current, flexible and scalable as possible. Brian Swindells of ICS Automation (centre) receives the Innovation award from Deon van Aardt and Tim Sowell.
Another end-user trend is the recognition that their companies should be unified entities focusing on the enterprise goal and that they should evaluate potential solutions in that light (this is evidenced by the selection of multiple solutions in a number of cases and the capitalisation on existing Wonderware solutions in others while making best use of past investments in all scenarios). The merging of industrial IT with business IT is at last making unified companies a reality ... because it’s all about information.
Nontle Nyombolo of Eskom (right) and Neels van der Walt and Machiel Engelbrecht (2nd and 3rd from left) of Bytes Systems Integration receive the International Invensys Environment and Safety award from Jaco Markwat (left) and Tim Sowell.
May/June 2012 | 75
76 | www.protocolmag.co.za
X-Change 2012 Report-back
May/June 2012 | 77
Use Protocol Magazine to generate business opportunities Protocol magazine continues to be well
you’re a solution supplier) or recognition
The Guideline is in the form of prompts to
received on a bi-monthly basis by 6500
(if you’re an end-user)
which you supply the answers to the best of
industry professionals like you, at every level of the country’s leading mining and manufacturing companies. You can
your ability. This, together with the graphical • It must generate market awareness of your capabilities
leverage this highly-qualified readership
information required, will be used to write the article which will be sent back to you for editing, approval, etc.
to be heard.
• It must do all that at a reasonable cost
How do you promote yourself right now?
Protocol magazine meets all these criteria.
The Permission to Publish form must be Some of the things you might be doing
signed by the end-user of the installation and system integrator / solution vendor
could include inserting opinion pieces,
If you’re an end-user, your stakeholders are
(if applicable) before work on the article is
adverts, editorials and other material
most interested to know how well you’re
started. This ensures that all the work that
into South Africa’s leading manufacturing
looking after their interests by lowering costs
goes into compiling the story will not be
and mining magazines. A good choice
and improving efficiency. Your colleagues
since these are excellent and professional
in the industry are keen to see how you’ve
publications that land on decision-makers’
implemented Wonderware solutions so that
You are free to use the completed success
desks every month.
they can evaluate if these will have the same
story in any marketing sense you wish and
benefits in their environments.
you have hundreds of examples on our
What Protocol offers is all the advantages
web site and in past issues of A2ware and
of a professional magazine with a large
If you’re a system integrator, end-users
circulation but the cherry on the cake is
want to know what you’ve done so that they
that all the readers of Protocol have one
can consider you as a solution supplier for
thing in common – Wonderware solutions
their next project.
Opinion Pieces: Once again, there’s no cost involved and
in the areas of SCADA, MES, EMI, BPM and enterprise integration – in fact, anything to
If you’re a hardware or software vendor,
you don’t have to worry about probably
do with industrial and corporate production
end-users and system integrators want to
not having majored in English. Decide on a
IT. Everything in Protocol is aimed at helping
know about how well your offerings work
central theme and the idea(s) you want to
end users get more from their Wonderware
in the Wonderware environment and how
put across, then jot down all the reinforcing
investment and trigger them to look at new
they can help them do a better and more
arguments you can think of (as well as
possibilities. Nobody wants to reinvent a
references if applicable). Also include any supporting graphics you feel will better
costly development or investigation wheel to stopping that happening.
What medium will work best for you?
Let’s think for a minute about your perfect
and what you have to offer will go a long way
illustrate the point. Send your draft article to your account manager
They won’t cost you a cent and you don’t have to write them. Simply send an e-mail
• It must convey your message in a
to your account manager stating that you
professional manner to a large, targeted
have the makings of a good story and why
and qualified audience
you think it is so. You will then be sent a
• It must generate incremental business (if
78 | www.protocolmag.co.za
and, if necessary, we’ll make the necessary edits before returning it to you for approval.
promotion vehicle and what it should do for
Comments to the editor, Q&As, Product and/or service information:
Guideline and a Permission to Publish form
Send your submissions to Denis your
to complete and return.
account manager and they (as well as the
Use Protocol Magazine to generate business opportunities
answers) will be published in the next issue
That makes you pretty special.
For all your advertising requirements –
That makes what you have to say significant
including the drafting of effective adverts
(if interesting and relevant).
from scratch – contact Heather Simpkins at Text – In Microsoft Word format
The Marketing Suite.
Graphics – In PowerPoint, Bitmap or JPEG format (the last two in the highest possible
In other words, what you have to say matters and we have made it as easy as possible for
So what are we really saying?
you to say it!
As an end-user or supplier of Invensys
You will be talking to people with the same
Wonderware and associated solutions, you
reality as you and who have the same
form part of the world’s largest ecosystem
problems and concerns.
resolution you have)
of professionals in the fields of industrial
automation and the delivery of actionable
So, what we’re really saying is, use Protocol
intelligence from the shop floor to the top
magazine to say what you believe needs
to be said.
Did you know that if you don’t talk to anyone, they’re not likely to talk to you or send orders? May/June 2012 | 79
2012 Training Schedule (Johannesburg)
Did you know that your bottom line is directly proportional to the effectiveness of your workforce?
InTouch Part 1 Fundamentals (includes New Graphics)
System Platform – Application Server (includes new graphics)
• 2 - 6 July
NOTE: The dates shown apply to training
• 7 – 11 May • 30 July – 3 August
at our offices in Bedfordview, Johannesburg. Regional training is
• 25 – 29 June • 3 – 7 September
presented on demand. A minimum of six delegates is required to arrange
• 23 – 27 July
• 27 – 31 August
Regional training venues:
• 1 – 5 October
Durban: Khaya Lembali,
• 8 – 12 October • 29 October – 2 November Morningside.
• 26 – 30 Novemberr • 19 – 23 November
InTouch Part 2 Advanced (includes New Graphics) • 4 – 8 June
Cape Town: Durbanville Conference
Historian (includes ActiveFactory and Wonderware Information Server)
Centre. Port Elizabeth: Pickering Park Conference Centre, Newton Park.
• 9 – 13 July • 14 – 18 May • 10 – 14 September • 18 – 22 June
As the owner of some of the world’s most popular, advanced and versatile industrial
• 5 – 9 November • 20 – 24 August
automation, information and MES software solutions, you’ll want to get the most
• 17 – 21 September
from your investment and that includes getting the best training in the business.
• 15 – 19 October
We routinely train about 600 professionals like you every year not only on how to use
• 12 – 16 November
our solutions but how to turn our product features into real business benefits.
• 3 – 7 December So, let us suggest a training curriculum best suited to your needs. For all your training requirements, contact Emmi du Preez at email@example.com or call her on 011 607 8286
80 | www.protocolmag.co.za
Support – Customer FIRST
Support – Customer FIRST Maximise asset performance
to meet contractual obligations to your customers and the loss of business that
Downtime costs businesses millions of Rand
- Customer FIRST support gives you options to maximise productivity by keeping your
In a nutshell ...
may ensue. • Customer FIRST also gives you access
operations running smoothly.
to Invensys technical resources to
Customer FIRST is not just technical
help you ensure that your system is
support, it’s a comprehensive
Outages, both planned and unplanned,
back to capacity in as short a time as
programme to help you manage your
are costly; businesses increasingly need to
possible. Our world-class global service
systems and protect your investments.
employ effective pre-emptive strategies
organisation is available locally, so the
to reduce risks and employ efficient and
help you need is never far away.
effective resourcing strategies to ensure that non-productive time is kept to a minimum.
Asset performance is not just about
Customer FIRST members enjoy the
maximising availability though; you need
many benefits of a closer collaborative
Customer FIRST is not just technical support,
to ensure that your assets are working to
relationship with Invensys.
it’s a comprehensive programme to help
their maximum potential. You also need
you manage your systems and maximise the
to minimise the risk to your business of
performance of your assets.
missed schedules, poor quality or regulatory violations, with the business consequences
Downtime hurts - Customer FIRST can help
• Responsive services • Depth of expertise
that may follow. • Proactive planning Customer FIRST gives you proactive remote
Even the most reliable equipment requires
health monitoring services to spot warning
downtime, perhaps for routine maintenance,
signs before problems occur and advanced
preventative maintenance, upgrades or
consulting services to tune your systems to
replacement. You need to ensure that
downtime is kept to a minimum and to
• Continuous performance monitoring • Emergency contingency provisioning • Deep discounts on hardware
as a result.
Customer first – our mission: your success
• Software and services
• Customer FIRST provides you with
ensure that there is minimal production loss
Customer FIRST membership gives you
These important elements make the
access to great hardware maintenance,
access to award-winning technical support,
Customer FIRST membership an
software maintenance and comprehensive
hardware and software maintenance
essential part of your business success.
lifecycle management services to help
services, lifecycle management and remote
you optimise your planned downtime and
Services, training and consulting services
minimise unplanned downtime events.
and much more. The programme provides you with comprehensive services and flexible
Recovery time is critical and any delays
options to choose exactly the right kind of
in acquiring either replacement parts, or
programme to suit your business needs and
the expertise required to quickly resolve
help you to maximise asset performance.
problems, can have a significant financial impact on your business.
• Customer FIRST provides you with timely
Support Telephone Number:
access to critical spare parts with the
0861-WONDER (0861-966337) or
ability to manage spares more easily and
0800-INVENSYS (Toll Free)
ensure the reliability of your systems. What’s more, extended downtime presents
other risks to your business such as failing
May/June 2012 | 81
On the lighter side Warnings found on retail goods
• On Tesco’s Tiramisu dessert (printed on bottom of the box) - DO NOT TURN
• “Some women get excited about nothing and then marry him.”
UPSIDE DOWN (Too late! You lose!) • On Taiwanese packet of space dust confectionery - FOR PLEASURE FROM
• “It’s not an optical illusion, it just looks that • On Marks & Spencer Bread
DEEPNESS PUT FULLY INSIDE AND
Pudding - PRODUCT WILL BE HOT
ENSURE ALL IS MOIST
AFTER HEATING (are you sure? Let’s experiment.)
way.” • “A leading authority is someone lucky who guessed right.”
• On a blanket from Taiwan - NOT TO BE USED AS PROTECTION FROM A TORNADO. • On a helmet mounted mirror used by US
• On a Korean kitchen knife - WARNING KEEP OUT OF CHILDREN. • On a string of Chinese-made Christmas
cyclists - REMEMBER, OBJECTS IN THE
lights - FOR INDOOR OR OUTDOOR
MIRROR ARE ACTUALLY BEHIND YOU.
• On a Taiwanese shampoo - USE REPEATEDLY FOR SEVERE DAMAGE.
• On a Japanese food processor - NOT TO BE USED FOR THE OTHER USE (now I’m
• “Hard work never killed anybody ... but why take chances?” • “Hire a teenager while they still know it all.” • “One good turn gets most of the blanket.” • “I had an IQ test. The results came back negative.”
curious.) • On the bottle-top of a (UK) flavoured milk drink - AFTER OPENING, KEEP UPRIGHT.
• “Remember: ‘i’ before ‘e’, except in • On Sainsbury’s peanuts - WARNING -
CONTAINS NUTS. • On a New Zealand insect spray - THIS PRODUCT NOT TESTED ON ANIMALS.
• “Inside every short man is a tall man • On a Swedish chainsaw - DO NOT
doubled over in pain.”
ATTEMPT TO STOP CHAIN WITH YOUR • In a US guide to setting up a new computer - TO AVOID CONDENSATION
HANDS OR GENITALS (what kind of consumer phone-call led to this warning?)
• “If two wrongs don’t make a right, try three.”
FORMING, ALLOW THE BOXES TO WARM UP TO ROOM TEMPERATURE
• On a child’s superman costume -
BEFORE OPENING. (Sensible, but the
WEARING OF THIS GARMENT DOES
instruction was INSIDE the box.)
NOT ENABLE YOU TO FLY.
• “Honesty is the best policy, but insanity is a better defence.” • “Drag the Joneses down to your level. It’s
• In some countries, on the bottom of Coke bottles - OPEN OTHER END.
• Packet of biscuits Australia - CONTENTS: THINGS
• On a packet of Sunmaid raisins - WHY NOT TRY TOSSING OVER YOUR
of payments.” • “Murphy’s Law only fails when you try to • “Reality is an illusion created by alcoholic
• “Love thine enemies... it really pisses them • “If you aren’t part of the solution, you’re a
WINNER! NO PURCHASE NECESSARY. DETAILS INSIDE (The shoplifter special!)
WHILE SLEEPING. • On a bag of Fritos - YOU COULD BE A
• “If you think nobody cares, miss a couple
FAVOURITE BREAKFAST CEREAL? • On a Sears hairdryer - DO NOT USE
BISCUITS AND NUTS AND BISCUITY
• “Sex is nobody’s business but that of the • “Marriage is one of the chief causes of
three people involved.”
divorce.” • On a bar of Dial soap - DIRECTIONS USE LIKE REGULAR SOAP (and that would be - how?)
82 | www.protocolmag.co.za
• “A Freudian slip is when you mean one • “Ask not for whom the bell tolls, let the machine get it.”
thing and say your mother.”
On the lighter side
• “Start off every day with a smile and get it over with.” • “A good pun is its own reword.”
• “The sooner you fall behind, the more time you have to catch up” • “Never put off until tomorrow what you can avoid altogether.”
• “Monday is an awful way to spend 1/7th of your life.”
• “What goes around usually gets dizzy and falls over.”
• “When it comes to thought some people stop at nothing.” • “All general statements are false.”
• “When in doubt, give advice.” • “After all is said and done, usually more is said.”
• “Hellrung’s Law: If you wait, it will go away.” • “Complex problems have simple, easy-to• “Every silver lining has a cloud.” • “The real world is a special case.”
understand wrong answers.” • “The Two Rules of Success: 1. Don’t tell everything you know.”
• “Most people deserve each other.” • “A man who smiles when things go wrong • “Nostalgia is okay but not what it used to
knows who to blame.”
be.” • “Behind every successful man stands a • “The hardness of the butter is proportional
woman waiting for his job.”
to the softness of the bread.” • “After things have gone from bad to worse, • “Seen it all, done it all, can’t remember
the cycle will repeat.”
most of it.” • “Adolescence is when children start • “If at first you don’t succeed, destroy all
bringing up their parents.”
evidence that you tried.” • “Be alert...the world needs more lerts.” • “Experience is something you don’t get until just after you need it.”
• “We are the people our parents warned us about.” - Jimmy Buffett
• “There are three kinds of people: those who can count and those who can’t”
• “For every action, there is an equal and opposite criticism.”
• “The colder the X-Ray tube the more of your body is required on it”
• “No one is listening until you make a mistake.”
• “Being superstitious brings bad luck” • “If you can remember the ‘60s, then you • “Get the facts first, then panic.”
• “The reward for a job well done is more work”
May/June 2012 | 83
Protocol Crossword #54 When you’ve completed the crossword, the letters in the coloured boxes spell out what Invensys Operations Management calls its all-inclusive enterprise control system. Note: This magazine contains the answers to a number of the clues. E-mail your answer to: firstname.lastname@example.org. The sender of the first correct answer received will get a hamper of Invensys Wonderware goodies.
Clues across: 1. The combination of information, knowledge and experience necessary to make the right decision (12) 9. Wonderware solution for quick and easy production reports (follow the arrow) (3,7) 11. Gas that can be colourful (4)
64. Aluminium symbol (2)
50. Roman Catholic (2)
65. The act of broadcasting information to those who
51. Eskimo (6)
need it (13)
52. Pro (3)
70. Wonderware SPC solution (2,7)
54. Second world war threat to allied naval supply lines
71. Blood suckers (4)
(1-4) 55. The book “The Hitch-hiker’s guide to the galaxy”
12. The material from which metals are extracted (3)
13. Time interval (4)
1. System Platform component responsible for the
14. Frequently flooded area of land (3)
distribution of information (follow the arrow) (11,6)
15. Application that provides reports on virtually any
2. Indicates maiden name (3)
mobile device (10)
3. 1000kg (3)
18. A guy could be said to have them for a girl he likes
4. Printing measure (2)
5. If a workman was to mislay his hammer, for example,
20. This country initially (2)
it would be known as a ____ ____ (4,4)
21. Liquid meal starter (4)
6. Smallest Indian state renowned for its tourism (3)
22. The part of the information process described in this
7. To sin (3)
issue of Protocol deals with this (9)
8. They catch fish (4)
25. Low Tension (2)
9. High regard or great respect given, received or
27. Submerged version of UFO (3)
28. Come together with (someone) (4)
10. Slimy substance generated by humans or animals
29. Transparent (5)
31. Operators often can’t do their jobs properly because
13. Possesses (3)
of too many reported emergencies. This can be
16. Magnetic Source Imaging (3)
described as __________ _________ (5,7)
17. Imperial measure of approximately 5 litres (6)
36. High Tension (2)
18. Car tweaked for extra speed (6)
37. The act of bringing together diverse bits of
19. Alternative word (2)
23. Slippery fish (3)
38. Flower (4)
24. This as opposed to war (5)
40. Cooled to freezing point (5)
26. Beverage (3)
41. Throws or hits in a high arc (4)
29. Gay cupboards? (7)
42. Constricting throat wraps? (4)
30. Spanish for “’til God” (5)
43. Not odd (4)
32. Small liquid measure (abb.) (2)
45. Large flightless birds (4)
33. Girl’s name (7)
46. Transport Protocol (2)
34. English Public school (4)
51. Information Technology (2)
35. Woman was allegedly made from one (3)
52. Enemy (3)
36. It stores process data in real-time (9)
53. Knowledge based on sound information leads to
39. Egyptian sun god (2)
improved ______ ________ (8,7)
42. Belch (4)
57. Local Thermodynamic Equilibrium (3)
43. Not good (4)
58. Operatic solo with instrumental accompaniment (4)
44. Undershirt (4)
59. Retirement Annuity (2)
47. Flower part (5)
61. Pay or persuade someone to commit an unlawful act
48. Storage Device (2)
such as perjury (6)
49. Same as 23 down (3)
84 | www.protocolmag.co.za
says not to do this on its front cover (5) 56. The US-led war effort there ended in December 2011 (4) 57. Noise (3) 61. Cell phone message (3) 62. Binary Number (2) 63. Real Time Integration (3) 65. District Attorney (2) 66. Scientific American (magazine) (2) 67. Software Library (2) 68. Ernst & Young (accounting firm) (2) 69. Bone (2)
Answer to Protocol crossword #53: Question: What’s the goal of the information process? Answer: KNOWLEDGE
with your artistic side that craves performance
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