SCADA is DEAD. The Case for Rethinking Your Approach to Automation. Speakers: Dean Ford, CAP, PE

Transcription

1 SCADA is DEAD The Case for Rethinking Your Approach to Automation Standards Certification Education & Training Publishing Conferences & Exhibits Speakers: Dean Ford, CAP, PE 2016 ISA Water / Wastewater and Automatic Controls Symposium August 2-4, 2016 Orlando, Florida, USA

2 Presenter Career built upon using Automation to deliver cost effectiveness in operations Certified Automation Professional Licensed Control System Engineer in 15 states 20+ years of pushing automation to deliver its maximum value to organizations Active Promoter of the Profession Senior Member of ISA Aug 2-4, 2016 Orlando, Florida, USA 2

3 Presentation Outline Major Trends Aging Workforce Convergence of IT (Information Technology) and OT (Operational Technology) Shrinking budgets with increasing demands Stimulate Thought about what SCADA actually is Look at SCADA as a tool to return investments made Aug 2-4, 2016 Orlando, Florida, USA 3

4 Definition Setting the Stage What is SCADA? Supervisory Control and Data Acquisition Designed primarily for Data Acquisition and Visualization Comprised of PLCs, DCSs, HMIs, Historians, Networks, Instrumentation Aug 2-4, 2016 Orlando, Florida, USA 4

5 Definition Setting the Stage What is Automation (Process Control, Industrial Control)? Designed primarily with Reliability, Consistency and Cost Reduction in mind. Data and visualization is there by default. Comprised of PLCs, DCSs, HMIs, Historians, Networks, Instrumentation Why are we treating them differently? Aug 2-4, 2016 Orlando, Florida, USA 5

6 Definition Setting the Stage Operational Technology (OT) Real time Required High availability or people get hurt HMI, PLC, DCS, Radio s, Control Network Information Technology (IT) Transactional Perceived need for high availability or people can t read their , website, customer billing, financial, ERP Aug 2-4, 2016 Orlando, Florida, USA 6

7 Automation is MISSION CRITICAL Aug 2-4, 2016 Orlando, Florida, USA 7

8 Operational Data Management Aug 2-4, 2016 Orlando, Florida, USA 8

9 Asset Lifecycle Like pumps, pipes, and valves, Automation has an asset lifecycles BUT they are shorter and have planned technology obsolescence challenges. Aug 2-4, 2016 Orlando, Florida, USA 9

10 Starting a Discussion Why are we killing SCADA? Limits our thinking to data acquisition It s a mental block, not a technology issue Vast capabilities that are not being taken advantage of Convergence of OT and IT Aging workforce, need to recruit from outside Your organization (and rate payers) have likely made huge investments in Automation disguised as SCADA. Shouldn t we take advantage of all the benefits available? Aug 2-4, 2016 Orlando, Florida, USA 10

11 Major Trends Aging Workforce Look around the room How many of you graduated with Automation as a career? What is the average age of the room? How many are retiring in the next 5 years? Lacking Automation Engineering Curriculum Declining STEM (Science Technology Engineering Math) enrollment Shift in Technology forcing increasing skills to support Can it still be done by one person? Aug 2-4, 2016 Orlando, Florida, USA 11

12 Major Trends IT and OT Convergence Is your Automation System part of your IT infrastructure? Who is responsible for it? Why? Who s mission is more aligned with managing and using data? Where is all the data? We need to drive to a single version of the truth. The truth already exists in the automation layer. Aug 2-4, 2016 Orlando, Florida, USA 12

13 Major Trends IT and OT Convergence We are using the same equipment. Switches, routers, servers, virtualization Offload non-value tasks and responsibilities to those that are better suited for it. Stay focused on where we add the most value, the Control Layer. A single organization does not need two sets of IT professionals. Aug 2-4, 2016 Orlando, Florida, USA 13

14 Major Trends IT and OT Convergence Who sets the Control Strategies? What is the value of improved control? Who is responsible to use the tools to drive costs out of the operation? Stay focused in making Operations operate more effectively. Track your improvements, make them real. Aug 2-4, 2016 Orlando, Florida, USA 14

15 Major Trends IT and OT Convergence Why Can t We Get Along? Traditionally, IT and OT have had difficulties in their relationship. We must overcome this. Aug 2-4, 2016 Orlando, Florida, USA 15

16 Major Trends Shrinking Budgets, Increasing Demands How can I do this when I have no budget? Automation Projects should self justify Can t say no to a project that pays for itself Need to track the value we provide We need Chief Automation Officers more than Chief Information Officers Need to learn the ways of financial and operational justification Don t let others claim your cost savings and other improvements Every Automation Professional should read and understand the true VALUE OF AUTOMATION* *Dr. Peter Martin s Books, The Value of Automation ISA 2015, Bottom Line Automation ISA 2006 Aug 2-4, 2016 Orlando, Florida, USA 16

17 Level of Capability Major Trends Shrinking Budgets, Increasing Demands Westin Automation Maturity Model Business In tegration and Optimization Local Hardwired Control Indicating Instruments Relays & Circular Charts Operations Cont rol Local Digital Control Loop controller/plc Local data loggers and OITs Control modes (local only) Remote Manual Control Digital controller Loop controller/plc Netwrok with central HMI/SCADA servers Control modes (remote-manual, local) Full Automation Process interlocks exchanged over network Automated closedloop control around setpoint Control modes (remote-auto, remote-manual, local) Enhanced Operations Operational flexability Historical SCADA data management Decision support system provides operator advice Control modes (remote-auto, remote-manual, local) Optimized Operations System-wide proactive control Tools for operations optimization analysis Business systems integration (SCADA, LIMS, CMMS, FIS, hydraulic model) Control modes (remote-optimized, remote-auto, remote-manual, Level 0 Level 1 Level 2 Level 3 Level 4 Level 5 local) Aug 2-4, 2016 Orlando, Florida, USA 17

18 Major Trends Shrinking Budgets, Increasing Demands We must keep our system evergreen Current common practice of run to failure and then Big Bang approach to upgrades is a waste of money and resources Opportunities are lost throughout the lifecycle Cybersecurity won t allow for the old way Need to adopt a cutting edge approach using innovation to solve the problem. We must root out and kill the mediocrity mentality in the industry Today s Automation requires constant and consistent maintenance to ensure it is providing all the benefits of the reliability required. Aug 2-4, 2016 Orlando, Florida, USA 18

19 Workforce Development A quick word about the Automation Workforce of the future Automation Profession today is built, not learned Market is very tight right now Need to keep the next generation excited about the work and the technology There is a lot of work going into the development of the next generation, and we aren t there yet. Aug 2-4, 2016 Orlando, Florida, USA 19

20 A Vision / Challenge for All of us We can minimize total cost of ownership of automation systems and the unit costs of operations while simultaneously increasing our customer service levels and lowering risk. Aug 2-4, 2016 Orlando, Florida, USA 20

21 A Vision / Challenge for All of us Information-Driven, Real-Time Decision-Making To do this, we must use information-driven, realtime decision-making made possible through the integration of systems, technologies and business processes. If an automated process or data transfer can be done, then we must justify it and execute it. Aug 2-4, 2016 Orlando, Florida, USA 21

22 A Vision / Challenge for All of us Elevate the Human We must minimize human interaction in running the plant. We must remove requirements for human interaction from our process control and routine operations. We must elevate Human Involvement to solving problems and making improvements. Aug 2-4, 2016 Orlando, Florida, USA 22

23 Summary We need to change the perception of SCADA It is a mission critical asset and must be handled as such We must form partnerships with support organizations We cannot possibly know it all well enough to do it well Automation Projects should self-justify and have a clear return on the investment Read Dr. Peter Martin s Books We must develop our future workforce Succession planning, recruiting, curriculum Aug 2-4, 2016 Orlando, Florida, USA 23

24 Important Resources References International Society of Automation ( Standards ISA18.2 Alarm Management ISA88 Process Modeling ISA95 Enterprise/Control Integration (B2MML) ISA99 Industrial Automation and Control Systems Cybersecurity (IEC62443) ISA100 Wireless Systems for Automation ISA101 HMI Automation Federation ( Automation Competency Model for Workforce Development Dean Ford, CAP, PE Aug 2-4, 2016 Orlando, Florida, USA