Reviewer details
Name: H vd Westhuizen
Position: Instrumentation supervisor
Company: MMC Nelspruit
Phone: +27 (0)13 759 4729
E-mail: [email protected]
Product details
Vendor: Adroit Technologies
Product(s): Adroit v6.2
Phone: +27 (0)11 658 8100
E-mail: [email protected]
URL: www.adroit.co.za
Application
Industry: Mining and metallurgical
Server OS: Server 2003 SP2
Client OS: Windows XP Pro
Front end(s): Modicon 984 PLC and Spectrum Teleranger telemetry system
Tag count: 1136 scan points
Updates per day: Not available
General
Q: Briefly describe the application including information on any pre-existing system that was in place.
A: MMC has implemented 12 scada machines each connected to one or more PLCs and telemetry stations. The PLCs range from old Modicon 984s to the latest Schneider Premium PLC. The PLCs all stand alone but the 12 scada machines are connected via an office network.
Q: Who performed the scada configuration?
A: Scada configuration is done in-house by the section instrumentation technicians.
Q: Approximately how many man-hours did the scada configuration take?
A: When the first Adroit package was bought ±10 years ago the initial setup including all planning and configuration took in the region of 160 man hours but with each new machine it has taken less and less time. Currently it takes not more than 40 man hours for an average size machine.
Q: Was a structured process followed to determine expected performance under full load and during abnormal failure conditions?
A: No, all machines and PLCs are powered using UPS power and can run independently from any network connection. The scada machines are used as an HMI – all control is done in the PLCs and the plant can run without the scada for short periods.
Q: What sort of licensing agreement applies to this particular system?
A: Each scada machine is licensed using a USB Hasp and this can be bought in the size required, from our smallest 75 scan point application up to our biggest 1500 scan point Hasp.
Q: What upgrade agreements are in place? Are patches and version upgrades free, covered under annual maintenance or managed in some other way?
A: Upgrades are covered under an annual maintenance agreement. MMC bought an all inclusive package which includes free licensing, upgrades and support to operators via telephone, fax, e-mail and web portal. This licensing also provides access to support tools, driver and software updates, patches and special prices on a variety of training courses.
Q: How is after-sales support handled?
A: After-sales support is done telephonically or via e-mail. This is sufficient in 99% of cases. In extreme instances Adroit will send down a support technician at an hourly rate.
System architecture
Q: What impresses you most about the architecture?
A: Adroit’s wide range of available drivers – all the drivers needed for our older and newest PLCs came as a standard. All upgrades up to Adroit 6 were accomplished by our section technicians without any process interruptions.
Q: What are the key physical communication layers and communication protocols employed in the system?
A: We use fibre, Ethernet, Modbus Plus and Modbus as communication protocols.
Q: Is the scada system integrated onto an intranet or the Internet? If so, what level of remote monitoring and control is configured?
A: All scada mimics are available on our intranet for remote viewing on all office machines if remote view is installed on the specific machine. This is done by controlled application forms only. These are specific MMC forms developed for this purpose which are stored on the local portal and require certain signatures before they can be accessed. For plant safety reasons we did not configure full remote control.
Q: Does the application utilise web services?
A: No.
Q: What redundancy is incorporated in this scada application?
A: Adroit Active Cluster technology.
Graphics
Q: Describe the graphics development process.
A: Graphics were developed using a combination of standard Adroit wizards and self-made wizards. Our mimics are drawn as far as possible to reflect a true plant view. We modified many standard wizards to fit each application.
Q: How would you describe the library of graphic images?
A: The wide range of graphic images (wizards) save a lot of development time and can be modified to site requirements.
Q: What human factors were taken into consideration in the HMI design process?
A: Views were made as true a replica of the plant as possible to make training and control easier for all production personnel and other scada users.
Q: Did you use any ‘special’ images or video technology?
A: We make extensive use of Adroit’s Plant VCR where historical data is required in incident investigations. This feature allows us to seamlessly switch between realtime and historical modes of a graphic to playback events as they occurred.
Compatibility
Q: Do you run the scada in conjunction with any third-party application software?
A: For the precise setting of control parameters we use SQL and Excel to read and write tag values. Values derived from analysers are read into Adroit, manipulated and then the results are written to the PLC as control set points.
Q: Was any custom code or scada scripting written for this project?
A: We used expressions to indicate four different drive motor statuses in different colours to help operators to easily identify problem situations.
Management reporting and integration
Q: Is a trending and historical data reporting system included
A: Yes, trending and historical data storage are strong features of Adroit. At MMC we keep historical data for the prior 35 days. Any trend point can be selected and exported to an Excel spreadsheet or can be viewed in the historical mode.
Q: Is a management reporting system included in the package?
A: No, this is available as an extra.
Q: Is the system integrated with an MES / ERP or other management reporting or control system?
A: No.
Q: Are any production benchmarking tools configured as part of the scada system?
A: No.
Q: Does the application include asset management functionality?
A: No.
Q: Does the application include GIS (geographic information systems) integration?
A: No.
System safety, security and data protection
Q: What alarm management standards or best practices were adopted in configuring the scada system?
A: We were careful to only alarm tags of real importance to the operating personnel. Alarms have been classified on their importance to the operator and are displayed in different colours to reflect this.
Q: How were the potential consequences of abnormal process conditions taken into consideration during the HMI design process?
A: Through alarm classification only.
Q: Does the design make provision for a DMZ and firewall segregation of process network and business networks?
A: Each scada machine is protected by a firewall and security to BHP Billiton standards. The scada machines form part of our intranet. The Windows operating system, applications and machine hardware are managed by our IT department. The same level of security is maintained as on all office PCs.
Q: What intrusion detection is incorporated on the plant network(s) on which this scada system exists?
A: Unanswered.
Q: What configuration backup and archive backup methodologies have been adopted?
A: All 12 scada machines are backed up via a scheduled daily backup to a server machine maintained by our IT department. Backups can also be made using remote logon to the server at any time of the day immediately after changes are made.
Conclusion
Q: What was the predominant feature(s) that made you decide to employ this scada, rather than another?
A: Adroit is a local company and its willingness to assist in special applications made it a sure choice for our company. Our contractual agreement means that we regularly receive new versions, which contain useful new features.
Q: What impresses you the most about the system?
A: Adroit is a very complete system, it meets all our requirements and the VCR feature is very handy in supplying data to all stakeholders.
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