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Plant Wireless Data Mobility

Plant Wireless Data Mobility. Mansour Al-Dajani, Ph.D. KFUPM, Dhahran 31261, Saudi Arabia dajani@ccse.kfupm.edu.sa for Saudi Aramco 2004 . Content. Why wireless? Objectives and goals Data Layers OPC standard PI package Wireless options Wireless Plant Monitoring System

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Plant Wireless Data Mobility

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  1. Plant Wireless Data Mobility Mansour Al-Dajani, Ph.D. KFUPM, Dhahran 31261, Saudi Arabia dajani@ccse.kfupm.edu.sa for Saudi Aramco 2004

  2. Content • Why wireless? • Objectives and goals • Data Layers • OPC standard • PI package • Wireless options • Wireless Plant Monitoring System • Pilot project: OPC-based SMS Alarm System • Demonstrations

  3. Why go wireless? • Improve communication • Greater mobility • Ideal in alarm situations • Convenient • No cables • Increase personalization • Can reduce cost • Can increase efficiency

  4. Objective: To link the plant information systems to the wireless voice/data infrastructure • Main Goals • To further increase the mobility of plant information for better service, quick decision making, etc. • To allow useful and sensitive data to reach sites where land-line communication is not available

  5. Scenarios • Acquiring/Receive plant data while in • Meeting rooms (world wide) • On-the-go (car, helicopter, train, etc.) • Non-Aramco-WAN sites (world wide) • Sites where no computers available • Security personnel is alarmed of activities inside the plant anywhere he may be • Security can even receive picture-frames or voice activity of sites inside the plant

  6. Cont. • Consultant can read Graphic production trends of a certain machine inside the plant. • Fire fighters are promptly informed of any fire alarms inside the plant anywhere they may be. • Power plant staff would like to be inform when shutdown or power outage happens in a certain power plant.

  7. Data Layers Enterprise & ERP (SAP etc.) Process Interface (OPC, PI, etc.) DCS/SCADA (Honeywell, Yokogawa, Siemens, Emerson, etc.) Plant Floor

  8. OPC Standard • Stands for OLE for Process Control • Released Aug. 1996 • Created by number of leading automation suppliers with Microsoft • Provides open, flexible, and plug-and-play software technology for process control • Platform Independent common interface communication between plant floor and MIS • Benefits • Better access for process data • Ease of plug-and-play operations • Reduced development cost and time • Greater freedom and variety of vendors solutions

  9. OPC Structure OPC DA Client (PC, HMI, Data Historian, OPC Gateway) OPC Client VB.NET, C#, VB, etc. (Protocol Stack, API) OPC Server OPC Server DCS/SCADA (Honeywell, Yokogawa, Siemens, Emerson, etc.) Plant

  10. PI™ System • PI™ stands for “Process Interface” • Developed by OSIsoft • Built on OPC standards • Provides services such as • Data Historian and storage • Data Computation/Analysis (PI-ACE) • Alarm and notification (PI-Alarm) • Web browsing • Interface to Enterprise Layer (SAP, etc.) (PI-RLINK) • Enterprise tools (SQC, etc.)

  11. Wireless Options LMDS 802.11a/g 802.16 802.11b 4G MMDS Data Rate Home RF 3G Blootooth GSM 2+/GPRS/EDGE ZigBee GSM/IS-95 Range Plant Wireless Data Mobility Dr. Mansour A. Al-Dajani

  12. Wireless Plant Monitoring Alarms DCS/ SCADA OPC/ PI Instrument Readings GSM/3G Gateway (SMS/ EMS/MMS) Service Provider (STC, Etisalat) Machine Operation Production Information Inventory Information Aramco Wireless Network LAN/WAN (e.g. 802.11b) Plant Layer

  13. Audio/Video Monitoring Service Provider (STC, Etisalat) MMS/GPRS /3G Gateway Pictures/ Video Audio/ Video Interface Audio/ Image Processing CCTV Voice Aramco Wireless Network Plant Layer VoIP, VdoIP LAN/WAN (e.g. 802.11b)

  14. Things to keep in mind • Reliability • Data Security • Utilization of current infrastructure (SCADA, PI, OPC, LAN/WAN, WiFi, GSM SMS gateways, CCTV, etc.) • Minimum added-cost • Customization and flexibility • Future technology (3G, VoIP, Video-over-IP, etc.) • Two-way versus one-way communication • In-house versus out-sourced development

  15. Who May Use the System • Oil and Gas personnel • Operators/Engineers • Admin • Power Plant Personnel • Operators/Engineers • Admin • Security • On-road personnel • Admin • Fire Fighters • Future Needs?

  16. Some Limitations • Mobile coverage and security • Wireless devices may not be intrinsically safe inside the plants • Cost of providing employees with mobile devices • Availability and reliability

  17. SMS Infrastructure XML Email Exchange Front/End SMS Gateway Servers Riyadh STC SMPP SAP DDN Aramco Network PI? GSM SMS-C Firewall at Riyadh OPC? Dhahran Saudi Aramco Network

  18. Plant Data Source Options • SCADA/DCS • Proprietary • Different • Costly • Closest to the plant • OPC • Open Standard • Simple • .NET and XML programmable • Compatible • Still close to the plant • Needs in-house programming • PI • Proprietary • Costly • Not ready yet • SAP

  19. Pilot Project(OPC-Based SMS Alarm System) • To demonstrate the idea, a pilot project was built. • Built in-house • Used .NET environment • The solution goes through the following • Schedules alarm events • Reads plant data from the OPC servers • Keep track of this data • Makes decisions on Alarm situations • Sends SMS via Aramco-SMS Gateway • Sends Email messages

  20. Pilot Project Structure Email Server DCS/ SCADA ----- OPC Tag Readings XML SMS Gateway STC .NET .NET programming was done here SMS Devices

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