DECEMBER 2016
Inside: SCADA is not a middleware Three steps to get started IIoT analytics solutions & platforms
Supplement to Periodicals Publication
input #104 at www.controleng.com/information
The Industrial Internet of Things (IIoT) is transforming the manufacturing industry as we know it. Control Engineering, Oil & Gas Engineering and Plant Engineering are partnering with industry experts who present an in-depth look at IIoT-related issues, strategies, and opportunities. The IIoT webcast series offers four educational webcasts packaged with continuing education credits available for free. Now on-demand, register at www.controleng.com/IIoT
Webcast One: Effective Change Management
Effective IIoT integration includes technology and changing the way plants operate. The convergence of operational and information technologies are crucial to successful IIoT deployment. This Webcast looks at how to manage these changes and bring about a company-wide commitment to an IIoT strategy. Presenter: Stan Schneider, Industrial Internet Consortium GE Digital
Event Sponsors: Now on-demand, register at www.controleng.com/IIoT
Webcast Two: Information Management for IIoT
With the existing network of sensors and gauges on the plant floor today, getting data has not been the issue. The challenge for manufacturers is to analyze that information to allow manufacturers to make better plant floor decisions. This Webcast discusses how data management can lead to better and faster decision-making and better asset management. Presenter: Sal Spada, Research Director, ARC Advisory Group Event Sponsors: Now on-demand, register at www.controleng.com/IIoT
Webcast Three: Security for IIoT
CFE Media research says data security is a top-of-mind issue. Threats exist from internal and external sources, so manufacturers need a robust strategy to understand the source of threats and how to be prepared to ward them off. This Webcast will look at the issue of data security from all aspects. Event Sponsors: Now on-demand, register at www.controleng.com/IIoT
Webcast Four: IIoT case studies: strategies in action • Thursday, December 15, 2016
Organizations promoting IIoT strategies are working on case studies to show related beneďŹ ts. In a list of 20 major technology areas, CFE Media research found that IIoT ranked the highest for potential to increase productivity, and the lowest for having already changed how end users work. This Webcast will review best practices, showing how the strategies have been implemented into operations. Event Sponsors:
Register for the IIoT series today at www.controleng.com/IIoT
Better Data, Better Decisions Kepware’s software supports connectivity to thousands of devices and data sources—providing real-time industrial data to all of your applications and enabling smarter decision making throughout the enterprise. Learn more at kepware.com/CE
input #105 at www.controleng.com/information
DECEMBER 2016
As the cover graphic suggests, IIoT technologies could be seen as an alternative to the traditional automation triangle comprising control, execution, and enterprise levels.
EDITORIAL
4 Next steps in IT-based automation and operations Welcome to the CFE Media special edition COMMENTARY
5 What is Ethernet’s role in Industrial Internet? Applications demand sensible migration path and robust network
FEATURES
6 How IIoT happened at Hirotec Tactical engagements support a strategy for better data use
9 IIoT analytic solutions and platform suppliers There are as many things to know as there are questions to ask
12 SCADA is not a middleware How IIoT changes SCADA and improves operations
6 Future Apps & Integration Historian
SCADA Host
DMZ
Analytics & Big Data
MQTTEnabled MessageOriented Middleware
Electronic Flow Measurement ERP
Edge of Network Controller
Edge of Network Controller Mobile Apps Asset Management & Optimization
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“Enterprise (IT)”
Native MQTT Device
“Operations (OT)”
17 The first three steps are always the hardest
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Accelerate the value of an IIoT strategy for enterprise assets
20 Out of the box Answers about IIoT for controls COMPOSITE COVER DESIGN by Michael Smith, CFE Media. Images courtesy of Bosch Rexroth (background), Canary Labs (top of pyramid), Beckhoff Automation (middle of pyramid), and, left to right on the bottom, the HMI, controller, drives and motors (Lenze), and proximity sensors (Turck).
www.controleng.com/IIoT
Industrial Internet of Things
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PRODUCTIVITY & BEST PRACTICES: EDITOR’S COLUMN Kevin Parker Senior Contributing Editor
Next steps in IT-based automation and operations Welcome to the CFE Media special edition, IIoT for Engineers.
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The unfolding of the Industrial Internet of Things can be looked at from numerous angles. IIoT combines advances in sensors and devices at the process level, enhanced connectivity across operations and execution, and analytics availability for decision makers. As the edition’s cover illustration suggests, one way to look at IIoT is as an alternative to the traditional automation triangle of control, execution, and enterprise levels. The IIoT for Engineers special edition, which will appear four times in 2017, is about the use of information, automation, and Internet technologies to improve productivity in discrete-manufacturing and process-production industries. Engineers are the backbone of our industrial management and executive ranks. Technicians, engineers, managers and executives know better than most that computerization changes the nature of their work, and are very comfortable freely mixing engineering, automation, Information technology (IT), and management vocabularies. In addition, we hope readers from IT backgrounds will be drawn to the publication to familiarize themselves with concepts related to discrete manufacturing, process production and supply chain management. DECEMBER 2016
Supplement to Periodicals Publication
Market snapshot Another aspect of IIoT is that unlike some integration technologies proposed over the years, IIoT embraces legacy systems and the installed base. Progress can proceed from “the bottom up.” In other words, as noted in the edition’s case study, innovation is achievable by mid-size enterprises. The level of capital investment involved doesn’t necessarily require a corporate initiative. In this it resembles the supervisory-control (SCADA) markets that grew so precipitously in the 1990s. At the device level, new generations of multi-parameter and industrially strengthened sensors are being introduced,
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as well as Internet fieldbus and protocols, advanced Internet switching, and a range of embedded systems. Automation and IT suppliers have brought IIoT technologies together as products. IIoT connectivity suites ease the pain of machine and application integration. Analytic suites apply themselves to asset management and other optimization tasks. As product categories, their boundaries can overlap, but the special edition includes a brief impressionistic listing of the kinds of analytic Inside solutions coming to market based on the IIoT opportunity. The “things” that IIoT refers to are uniquely identifiable objects. Their virtual representations, combined with middleware and a service orientation, allow machine-to-machine communication among computers, embedded processors, smart sensors, actuators and mobile devices, with limited human intervention. In general, the challenge is that industrial enterprises have more than enough data. To better support decision makers, IIoT technology brings the data sources together, in the Cloud, and then parcels the information back out in a roles-based, comprehensible context. Application spaces being addressed include predictive maintenance, advanced process control and operations optimization. Often the point is to have a single interface that melds automation elements and the IT network, or a maintenance with an operations view. SCADA is not a middleware Three steps to get started
IIoT analytics solutions & platforms
Better Data, Better Decisions
Learn More Inside >
Closing remarks It is true that some of the emergent technologies mentioned above are already in use for years. You reach a point, however, when the sum is greater than the parts. It’s also true that engineers and enterprises have been achieving connectivity and doing analytics a long time. That’s hardly surprising since what engineering disciplines always have done is to use accurate measure to achieve better judgement. IIoT www.controleng.com/IIoT
IIoT: TECHNOLOGY VIEWPOINT
What is Ethernet’s role in industrial Internet? Applications demand sensible migration path and robust network Visibility and control of connected IIoT objects calls for high-performance, low-latency networks with remote management capabilities. Today’s industrial networks, however, largely use specialized network protocols and have diverse installed bases. This makes modernization to an IP Ethernet infrastructure complex. Meeting challenges related to system reliability, determinism and security calls for using Ethernet switching solutions, programmable devices, high-precision timing, Power over Ethernet (PoE) and application-optimized software.
Industrial network security Industrial network security is typically premised on fire-wall isolation from a corporate network and the Internet. In fact, isolation makes it less secure and harder to manage. IIoT network security must be multilayered to protect the data, management, and control planes, particularly for M2M communications. A typical approach relies on data encryption; traffic control; authentication, authorization and accounting (AAA); and data integrity. As to networkwide encryption, MACsec (IEEE 802.1AE) and Keysec (now part of IEEE 802.1X) are the L2 encryption and key management protocols to secure Ethernet physical ports and VLANs. Further enhancing confidentiality, IEEE 802.1AEbn includes strong 256-bit encryption now required www.controleng.com/IIoT
by certain government agencies. While encryption alone is insufficient to secure a network, using strong 256-bit encryption like MACsec in networking equipment and end points is a means to authentication, data integrity, and user confidentiality.
Determinism delivered For deterministic performance and network reliability, the expectation is that specific functions occur within a precise timeframe. This is possible when each network element is timeaware and recognizes whether it delivered Ethernet packets “on time.” But this is only one part of the solution. A mechanism to synchronize and distribute precise “time” in Ethernet exists today using IEEE 1588v2; however, the latest Time Sensitive Networking (TSN) standards bring system developers a very time-oriented style of traffic scheduling. Developed by the IEEE 802 group, TSN standards broaden Ethernet capabilities to make it a true industrial-grade, real-time communications protocol. Elements include clock synchronization, time-based message handling, frame preemption and seamless redundancy. Besides usability and performance, for example, IEEE 802.1ASbt adds one-step time stamp support. Reduced packet numbers are needed to convey network timing information versus a two-step process in the prior generation standard.
The TSN features give Ethernet networks the real-time determinism and low latency needed, and should remove the last barrier preventing an IIoT network using Ethernet as its main backbone.
Network migration The eventual migration of IIoT networks to IP/Ethernet is a given, but recognize that components and systems for Local Area Networks (LANs) are not a natural fit for IIoT networks. For networks comprised of heterogeneous legacy equipment, using multiple specialized network protocols, key elements include: Multi-protocol support of Ethernet and fieldbus interfaces Optimized Ethernet switch software stacks Unified hardware and software Port configuration and synchronization options meeting IIoT environmental and operational requirements Power over Ethernet (PoE) options All this is possible with a pragmatic combination of hardware and software. It is important to note that there will be no “one-size-fits-all” approach for IIoT systems. IIoT Uday Mudoi is a vice president with Microsemi Corporation. Industrial Internet of Things
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CONNECTIVITY & COORDINATION: CASE STUDY
How IIoT happened at HIROTEC Tactical engagements support a strategy to make better use of data
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Tier-one automotive supplier HIROTEC recently completed a successful test-bed application project that exploits the latest technology advances in industrial connectivity and analytics. The newly implemented system melds operations and maintenance data, and by doing so, it can help employees identify trends that lead to contextualized, actionable insights. Moreover, HIROTEC managers say they are building a plant-floor technology infrastructure aimed towards the future. “The idea of making use of the Industrial Internet of Things [IIoT] as a platform arose organically, but then it had to be ‘sold’ to internal stakeholders,” Justin Hester, research and development project manager, said. A supplier of car enclosures and
exhaust systems, the HIROTEC Group is a $1.6 billion corporation with 26 facilities in nine countries. It builds roughly 7 million doors and 1.5 million exhaust systems a year. It is also a tooling company and provider of automotive tooling facilities.
The chosen challenge HIROTEC AMERICA, the HIROTEC shop in Detroit, was chosen as the project test bed because of the significant integration challenge posed by the unique data types generated by eight different kinds of computernumerical control (CNC) machines. “On the one hand, we’ve collected data throughout our history, both on the production side and the tooling side. But although great emphasis was placed on collecting data, not only weren’t we getting all the data
from tooling company clients, our own data wasn’t in a form needed to support timely business decisions,” Hester said. “The quality assurance and maintenance departments placed great store by their data, but didn’t share it with each other in a meaningful way.” One result of having these silos of information could be, for example, that managers didn’t realize until too late that the defects found on some manufactured doors were caused by a concurrent robot maintenance problem. The real-time nature of the new IIoT solution would address this challenge. In general, said Hester, the situation at HIROTEC was much like that found in many plants today. Almost everyone is familiar with the “Tuesday morning meetings” that take place in many manufacturing or production facilities. In these meetings, everyone involved gathers around the prominently displayed key-performance indicator charts to review Monday’s production. Important things come out of those meetings, “but it’s a simple fact that by then it’s too late to address Monday’s challenges,” said Hester.
Project approach FIGURE 1: Automotive supplier HIROTEC America recently demonstrated that meaningful integration to an IIoT connectivity platform could be achieved across all the different CNC machines found in its shop. (Photo courtesy PTC).
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PTC, a computer software and services company founded in 1985 and located outside Boston, provided the solution used by HIROTEC. PTC www.controleng.com/IIoT
is well known for its computer-aided design (CAD) and product-lifecycle management (PLM) solutions. Its acquisition of ThingWorx in 2014 and Kepware in 2016, as well as that of Adexa and ColdLight, position PTC as a significant player in emerging IIoT technology markets. In ThingWorx, PTC has an analytics platform developed by a team with deep roots in the production industries. Kepware brings solutions from a company with many years’ experience enabling integration of an installed industrial base with the latest control and computing elements. The IIoT PTC solution at HIROTEC includes the following elements: ThingWorx IoT Platform–set of integrated tools and capabilities for IoT solutions, including analytics for realtime anomaly detection at the edge, predictive analytics, and simulation. Kepware KEPServerEX–solution for device-to-cloud interoperability, acting as a single source of industrial automation data to multiple applications allowing users to connect, manage, monitor, and control diverse automation devices and software applications through one intuitive user interface. IoT Gateway for KEPServerEX– agent leverages the 150+ communications drivers within KEPServerEX to move real-time industrial data on the edge into ThingWorx. The PTC solution gives HIROTEC technicians, engineers, and managers access to real-time, role-based visualizations of the plant floor network’s current state, including electronic and industrial devices. “Kepware is how we get the data into the ecosystem,” said Hester. “ThingWorx is our engine for data analytics and machine learning. We www.controleng.com/IIoT
FIGURE 2: The interface provided to managers and technicians by means of enhanced integration tracks machine uptimes and profiles the complex machine states involved. (Photo courtesy PTC).
like that ThingWorx can either be on-premise or in the Cloud.” said Hester. HIROTEC already made use of Windchill, PTC’s PLM platform. It was therefore easy also to connect to engineering math data, said Hester. “At that point the idea of the model or a digital twin as a management concept becomes very real for us. PTC also has an augmented reality tool–Euphoria–that we can use to train operators and technicians.”
Implementation notes As an implementation task, “IIoT isn’t like ERP,” Hester said. “It matches the way we do business, not the opposite, and that’s very important.” Supported by PTC, HIROTEC assembled its IIoT framework using the SCRUM method, aimed at achieving
fast implementations via “agile” sprints. In this case, the sprints were of 6-week durations. SCRUM methods are typically applied to software development as an iterative and incremental framework. A key principle is that project parameters will change during development, and thus progress can be more important than initial comprehensiveness. The method delivers substantial benefits, Hester said. “We approached it as a software project, not a capital hardware project,” Hester said. “We fund these smaller projects and use them as a proof of concept. In each instance, we may spend hundreds of thousands of dollars, but we’re not committed to spending millions.” An ancillary benefit is that to move forward, “we don’t necessarily have Industrial Internet of Things
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CONNECTIVITY & COORDINATION: CASE STUDY
to elucidate a vision for where the company will be in 10 years. There’s flexibility this way, and it’s easier for interested parties to understand what we’re doing,” Hester said. As mentioned, of special interest to the initial project was to demonstrate that meaningful integration could be achieved across all the different CNC machine types at HIROTEC America. Besides being of different types, the 60 machines were also of different vintages. Thus, although CNC technology has only been around for decades, given the current speed of technology development, the machines already represented different technology eras. It was easy to connect the different machines’ device protocols into the common system, Hester said. “Kepware just does it, so there wasn’t any reason for us to dive further into it than that.” However, Hester noted, it’s a truism that “it is the machine that breaks that everyone knows best. We just put everything into Kepware. It worked so well that we didn’t bother to map out the network. We didn’t realize our mistake until we went to add a machine and didn’t have a port for it. Then we had to go back and create the needed network map.”
Other stakeholders One internal stakeholder in the project that Hester and his colleagues were intent on getting support from was the informationtechnology (IT) department. “It was helpful to engage with IT up front. So often, too often, information technology departments have projects thrown over the wall to them and then they are told it was needed yesterday,” Hester said. By engaging with the IT department immediately, departmental as-
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sociates were more supportive of the project. “Firewall and server issues were addressed expeditiously, servers came on line quickly, connection to the cloud was made in less than a day,” Hester said. “Audits didn’t have to be performed after the fact.” Another set of stakeholders are the system users. As with the CNC
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The newly implemented
system melds operations and maintenance data, and by doing so, it can help employees identify trends that lead to contextualized,
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actionable insights.
machines, stakeholders are of different types. “If you’re investigating an occurrence, the analysis is timelier and more complete if everyone finds the data in a familiar context,” Hester said. “For a design engineer, that means a CAD or PLM platform, for the operations manager that means SCADA or a manufacturing execution system. The ability to do that for the users was a benefit.” The interface provided both tracks machine uptimes and profiles the complex machine states involved in a way that can be intuitively grasped by operators, engineers, and managers. Engineers can compare the performances of different machines. Investigations can uncover linkages between maintenance anomalies and quality, operations, or production challenges.
Clearly, however, what Hester likes is that “we have a solution that can be scaled to address different challenges.”
Final words Hester is now working on a second IIoT project. At HIROTEC Japan he is helping to develop an IIoT application that involves 50-point inspections of advanced robotic systems. Industrial suppliers of many stripes, Hester noted, are introducing IIoT solutions aimed at specific maintenance or operations challenges. What HIROTEC wanted was an eco-system platform that addressed specific challenges but that also made strategic sense. With the solution, HIROTEC AMERICA increased visibility into its CNC shop processes and has deeper insight into operations. “With small IIoT projects there will mainly be ‘soft’ benefits,” Hester said, “although we’ve measured what we’ve accomplished. Once we were done, the plant and operations managers wanted it on their desktop immediately, as well as a display on the plant floor.” Having CNC machine uptime data improved shop scheduling, based on a solid understanding of past and current states. Manufacturing leverages real-time shop-floor data as an input to the ERP scheduling module, optimizing parts flow to the CNC modules. Greater insight into asset and resource allocations based on smarter questions about priorities helps determine the most effective course of action. The result is improved productivity at HIROTEC AMERICA. IIoT
Kevin Parker is a senior content manager at CFE Media. www.controleng.com/IIoT
ENTERPRISE ANALYTICS: SUPPLIER LISTING
IIoT analytic solution and platform suppliers There are as many things to know as there are questions to be asked
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The Industrial Internet of Things impacts almost all aspects of industrial IT-based automation. Yet it is being developed as a set of distinct capabilities. Some of the planet’s most prestigious industrial IT and automation suppliers recently have introduced IIoT analytic suites, packaged either as “solutions” that address a specific challenge, such as predictive maintenance, or “platforms” used to develop a range of solutions. Machine-and-equipment, asset-intensive industries generate, collect and store huge information amounts every day. Low-cost sensors and associated data streams mean data amounts will only increase. Harnessing that information to reveal unseen patterns can be transformational, these suppliers believe. They point to case examples in industry, as well as to the impact of analytics elsewhere, including in the sports world. Process and machine time-series data is different, however, and presents special challenges. It is continuous and granular. In format, it is multi-structured and requires real-time preparation to be presented in context. To have addressed these challenges is a stunning technology achievement. At the end of the day, there are as many things to know as there are questions to be asked. One benefit of introducing analytics into more and more work spaces is that the windows of opportunity for asking good questions will be widening to an extra-ordinary degree.
ABB Group, Ability Recently announced partnership with Microsoft for services such as Azure IoT suite and Cortana Intelligence suite includes applications in fleet management, intelligent buildings, integrated mining, and sensing technology. Advantech, Wise-Pacs Advantech is partnering with Microsoft Azure as the IaaS and PccS solution provider through the Microsoft www.controleng.com/IIoT
Cloud Solution provider program to offer diverse functions for IoT applications. Also offers an IoT gateway starter kit. C3 IoT, C3 IoT Applications Cross-industry software solutions aggregate volumes of disparate data from enterprise systems and external sources and apply advanced machine-learning algorithms for predictive, continuous analyses that culminate in actionable insights.
Cisco Systems, Industrial Network Director Purpose-built network devices; manage with real-time maps of automation device connectivity; network information delivered in the context of the automation process; existing assets integrated through APIs; common information framework shared by operators and IT to manage the industrial network. Dell, IoT Solutions Overlay intelligent gateways into existing legacy equipment, control systems, and assets. Deploy edge and core analytics. Deploy intelligent gateways across communications protocol networks and in the data center and Cloud. Emerson Process Management, Plantweb Advisor Suite Suite applications include Health Advisor, Performance Advisor, and Energy Advisor. All leverage OSIsoft PI System’s scalable open-data infrastructure to capture and shape data generated by equipment. The information can be vital to improving a plant’s profitability. GE Digital, Predix Industrial Cloud Platform A Cloud-based platform for Industrial Internet applications based on a multi-tenant gated community model Industrial Internet of Things
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ENTERPRISE ANALYTICS: SUPPLIER LISTING
to reduce equipment costs, enhances effectiveness of machine operators. Start by installing a Predix-ready field agent into your infrastructure.
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Harvesting data to reveal unforeseen
Honeywell, Uniformance Suite
patterns can be
Software solutions that turn data into actionable information. Correlates historian information with KPIs and a database all in one tool. Visualize information in an asset-centric context. IBM, Watson IoT Platform Easily and securely connect devices. Quickly build IoT applications that learn from the physical world. Analyze data from any source. Gain insight from huge volumes of IoT data to make better decisions and optimize operations.
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transformational.
OSIsoft, PI System Discover trends and best practices in process industries using operation data in Big Data analytics; analyze and visualize data. An open infrastructure connects sensor-based data, operators, and people to enable real-time intelligence.
INTEL, Intel IoT Platform
PTC, ThingWorx IoT Platform
An end-to-end reference model and family of products that work with third-party solutions to connect devices, deliver data to the Cloud, and value through analytics. A broad spectrum of interoperable, cross ecosystem IoT solutions can be bought and optimized.
Enterprise platform enables users to develop and deploy connected solutions. KEPServerEX provides a communications platform and single source of industrial automation data to multiple applications. ThingWorx agent in the IoT gateway moves industrial data from the edge into ThingWorx.
Meshify, Now Out of the box IoT solution minimizes barriers to deploy data gathering, analysis, and visualization. This product quickly connects a device to the Cloud to start analyzing data in minutes. Bundle makes use of M1 Dragonfly hardware. Microsoft, Azure IoT Suite Predictive-analytics and machinelearning applications include remote monitoring and predictive maintenance. Collect previously untapped data. Set up real-time analytics using SQL-based syntax. Integrate Azure IoT with CRM, ERP, and database applications.
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Rockwell Automation, FactoryTalk Production Centre The connected enterprise leverages embedded intelligence and new sources of information. Partners with Cisco Systems to bring network connectivity and operations systems together holistically in a single unified network infrastructure. SAP, IoT Solutions Data solutions apply machine learning and integrate with core business applications of SAP S/4HANA. A “jump start” package initiates operations/business connectivity to better monitor equipment and gain
Industrial Internet of Things
operational insights. An accelerator package adds MES and control environment. SAS, Analytics for IoT Whether your data is at the edge, in motion, or at rest, system supports good decision-making while reducing data transport and storage costs. Event stream processing engine handles huge volumes data at very high rates with extremely low latency. Schneider Electric Software, EcoStruxure Architecture and platform delivers IoT-enabled solutions by leveraging connectivity and data to create controls and actionable business insights. With the combined power of analytics and closed-loop operators, enables a breadth of applications, analytics, and services on open IP protocols. Telit, deviceWISE for Factory Developed to operate within the four walls of the enterprise, the platform connects and integrates production machines and processes with ERP, MES, and SCADA. Decreases installation and maintenance costs by eliminating the use of intermediate PC technology, custom programming, and homegrown solutions. Wonderware, Industrial Information Management As a plethora of new connected devices becomes available and the cost of instrumenting remote equipment plummets, the need for unifying systems to provide context and organize data is essential. A managed historian unlocks information. Data analysis tools make sense of industrial Big Data. www.controleng.com/IIoT
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T A Global System D P
Integrator Database
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SENSING & CONTROLS: TECHNOLOGY TUTORIAL
SCADA is not a middleware How IIoT changes SCADA and improves operations
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The term “supervisory control and data acquisition” (SCADA) refers to a set of industrial-software applications that can be configured to support management of almost any kind of discrete or process production. SCADA is found wherever it’s necessary to aggregate the data of a controlled process or to coordinate operations related to that production process. Will SCADA’s role change or diminish in an industrial automation world increasingly disrupted by the Industrial Internet of Things (IIoT)? The answer is no. In fact, IIoT
improves SCADA even before SCADA is ever connected to the Internet or Cloud. Use of Message Queueing Telemetry Transport (MQTT) message transport protocol, combined with message-oriented middleware (MOM) data brokers, “modernizes” SCADA infrastructures. Given the availability of IIoT connectivity solutions, instead of investing resources in re-engineering, re-integrating, and re-vamping SCADA based on 35-year-old protocols, time can be spent developing applications that take advantage of, for example, the cloud and analytics. In other words, IIoT technologies
can “leapfrog” over legacy infrastructures and the current installed device base with solutions and migration strategies that work in conjunction with them. Already today, fieldinstalled “edge” devices provide connectivity to existing PLCs, transmitters, and other nodes and publish real-time process variables using MQTT. MQTT is a bi-directional, lightweight, event-driven, message-oriented transport that allows devices to communicate efficiently across constrained networks to backend systems. MQTT eliminates so-called poll/response protocols, and by
SCADA host used as message-oriented middleware Future Apps & Integration Historian Analytics & Big Data
SCADA Host
Electronic Flow Measurement
Protocol X
ERP
Mobile Apps Asset Management & Optimization
“Enterprise (IT)”
“Operations (OT)”
FIGURE 1: Many modern SCADA systems still place the SCADA host system squarely in series with any field device using poll/response protocols.
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www.controleng.com/IIoT
leveraging mature MOM technologies, IIoT-enabled SCADA makes device data accessible to a wider range of information consumers. Devices no longer directly connect to, and are effectively decoupled from, the SCADA application. SCADA based on MOM principles reduces the latency of critical control and measurement data. Bandwidth previously required for poll/response is reduced up to 85%. That makes information often left stranded in devices accessible. In addition, it provides a single point of security management for field devices and applications, simplifies infrastructure topology for redundancy, availability, and scalability, and eliminates the dreaded “cutover” from one SCADA version to another. Finally, it provides the device decoupling required for additional IIoT enablement.
Legacy SCADA implementations Hardware-wise, a SCADA installation typically includes computer workstations, programmable logic controllers (PLCs), and instrumentation for system inputs and outputs (I\O). Another element of a SCADA installation is a distributed database and tag- or point-data elements. Each tag represents a single system input or output value. The process feedback loop passes through the PLC, while SCADA monitors loop performance. That is, PLCs assume parameter control, while operators monitor results and, for example, change set points. Peerto-peer communications among the controllers may be lacking. SCADA has remained basically unchanged over the last 40 years. Hardware and operating systems
improved per Moore’s Law, but its infrastructure and how information was put into it from devices and sensors remained largely the same. Most SCADA systems still place the host system squarely in series with any field device using poll/response protocols. These poll/response protocol drivers dictate that devices are connected directly to the SCADA host application. From an “operations” point of view these systems have proved viable. On the other hand, challenges arise whenever business functions want access to the data that smart devices and sensors furnish. To access it, additional polls must be placed into the SCADA host tables. Additional applications are needed to access the data. Security and accesscontrol parameters need to be in
Challenges in adding applications with traditional SCADA
Flow Computer
PLC
Electronic Flow Measurement
“New” Application
“Enterprise (IT)”
SCADA Host
Protocol X
“Operations (OT)”
FIGURE 2: When the enterprise requires additional applications from a process, additional polls are needed, as well as steps that include 1) creating a new application; 2) defining the interface/data scheme between the new applications and the flow computer; 3) modifying access control and define security; and 4) modifying the SCADA host poll tables to the flow computer. www.controleng.com/IIoT
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place. Operations must manage the additional polls and avoid any negative effects on update rates. Even then, SCADA is now gathering data it doesn’t need, just to pass it on to other applications. Over time, and primarily as means to operations coordination, SCADA comes to function more and more like message-oriented middleware, though it was never meant to do so. And as the SCADA host application evolves, it becomes brittle and difficult to manage. The efforts to benefit from additional information gathered from field devices come to a grinding halt. Past practices of connecting directly to SCADA using poll/response protocols also impede technology adoption. Once a protocol is deployed, users face a quandary when newer technology becomes available. Innovative devices may have proto-
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IIoT-enabled SCADA makes device data accessible to a wider range of information consumers.
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cols not supported by the SCADA. An alternative SCADA host cannot be evaluated in parallel with the current SCADA host on a live system. Connecting devices to applications using poll/response protocols makes point-in-time solutions difficult to update over time.
What can be done Using field network devices that implement MQTT natively, MOMbased SCADA can be realized, as
shown in Figure 3. Components of the legacy poll/response infrastructure are maintained. The primary change to the topology is the inclusion of the MQTT Server. Legacy devices in the field can be MQTT-enabled using available “edgeof-network” gateway devices that apply the native poll/response protocol and then convert the register/process variable information into MQTT messages published in real-time on a report-by-exception basis. SCADA devices available today already implement MQTT natively and can be added to an infrastructure immediately. Using MOM means end devices publish all operations data real-time, for consumption by SCADA and other business functions. Again, whether metadata, asset information, diagnostics, configurations, or other metrics, all are available in real time. The SCADA host is now decoupled
A MOM-centric SCADA architecture Future Apps & Integration Historian
DMZ
Analytics & Big Data
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Electronic Flow Measurement ERP
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Edge of Network Controller
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FIGURE 3: Using MOM-centric SCADA architectures enable devices to publish in real time to a MOM server, with SCADA participating as subscriber and publisher. Elements include 1) the MQTT message transport; 2) MQTT and other message transports; 3) A single-point DMZ for access control and permissions; and 4) SCADA as a data consumer, but not the only data consumer.
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from the remote field devices. The system is not limited by a specified poll/ response protocol implementation or SCADA host application. There is now a one-to-many relationship between field-device data being published and applications interested in subscribing to that information. The SCADA host can focus 100% on being a SCADA host rather than acting as a fragile middleware component–something it was never intended to be. All connections from remote sites to the MQTT broker are client-side originated and all remote sites, given normal operation, are all connected concurrently. Field devices became more intelligent in the last decade, but most of that additional intelligence is left stranded! The topology represented in Figure 4 is indicative of a modern SCADA with reduced bandwidth stress and allowing for a larger set of data.
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Why message-oriented middleware?
n use in the information-technology sector for more than a decade, messageoriented middleware (MOM) decouples applications. Legacy information technology systems worked much like SCADA poll/response protocols do today. Applications were tightly coupled, using protocol definition to determine how application A talked to application B. As a point-in-time solution these worked fine. But over time, tight coupling and strict definitions made it difficult, if not impossible, to update legacy IT applications. With MOM, on the other hand, applications publish data without concern as to who subscribes to it. Developers focus on creating value-add applications that publish and subscribe within a MOM infrastructure. In addition, with MOM, the payload of information published is defined by the message topic and not by a protocol; i.e., the payload of a MOM message is agnostic. It could be a binary JPEG file or it could be an XML document. Message transports let developers publish in the format that makes most sense for the solution, unconstrained by any protocol definition. This same infrastructure needs to be employed for IIoT-enabled SCADA. MOMcentric SCADA architectures let devices publish real-time data to a central MOM server. The SCADA host application participates as a subscriber to real-time process variables and a publisher of device commands. It also breaks the vicious cycle of protocol development and support since additional message topics can be created as required for evolving solution requirements.
The future state of SCADA SCADA SCADA Host Host Future Apps & Integration Historian Analytics & Big Data Electronic Flow Measurement ERP
SCADA SCADA Host Host
Field Devices (PLCs, RTUs, Smart Sensors, etc.)
DMZ
MQTTEnabled MessageOriented Middleware
Mobile Apps Asset Management & Optimization
FIGURE 4: Decoupling the SCADA host from a direct connection to field devices means a one-to-many relationship is established between data published and interested applications. The SCADA host acts as only that, a SCADA host.
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SENSING & CONTROLS: TECHNOLOGY TUTORIAL
Getting started MQTT was first released in 1999 as a SCADA-centric message transport but remained largely unknown in the wider markets. But over the last 4 years its use in IoT-focused solutions has gained considerable acceptance. Just about every messageoriented middleware product on the market today now supports MQTT natively. Open-source tools are available for MQTT, as well as tutorials and technical information. In the last 18 months SCADA device manufacturers, development-platform providers, and end-solution providers have announced some level of support for MQTT. To provide guidance and best practices about MOM-centric SCADA and migration strategies required for most existing legacy imple-
mentations, Cirrus Link Solutions created an open specification called “Sparkplug” that defines an efficient MQTT-based SCADA system. Sparkplug defines the standardized components needed for devices and applications to use MQTT in realtime SCADA effectively in terms of topic namespace, payload definition, and session state management. The specification is publicly available at a Github site along with simple reference implementation code in C, Java, JavaScript, and Python. Examples are provided for using the popular Node-RED visual-wiring tool. Using Sparkplug for efficient MQTT messaging and state management enables providers of SCADA host solutions and end-device manufacturers to seamlessly interact in real-time SCADA solutions. Applications can
Some notes on MQTT
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QTT was first used in the 1990s in mission-critical, real-time SCADA in the oil and gas industry. For most of these systems, VSAT technology was the primary communications network, and therefore bandwidth was minimal. MQTT proved attractive for use in SCADA because it is: Natively built on top of TCP/IP, with client-side TCP/IP session enablement Stateful, with continuous session awareness Bandwidth efficient Data-agnostic
“join” the infrastructure to quickly access available real-time information. Sparkplug reference implementation applications can be executed on a Raspberry Pi hardware platform connected to any open-source MQTT server. Production-quality infrastructures can be built out using solutions already implementing the Sparkplug specification including solutions from Inductive Automation, Node-RED, Advantech, Elecsys, Hilscher, Magnetrol, Moxa, Opto 22, and Tyrion. With this emerging eco-system available, device makers, SCADA developers, integrators, and end users can now build-out MQTT-enabled infrastructures as a basis for moving away from systems dependent on legacy poll/response. MOM is a well-tested, deployed, and accepted technology within the IT world today. Applying it to SCADA systems using MQTT results in an implementation that is modern and state-of-the-art, using more standard, off-the-shelf components and requiring less customization and application integration around the SCADA host application. Additional field device intelligence can be accessed and brought into line-ofbusiness applications without impacting or modifying the SCADA host application. IIoT
Simple to understand and implement. If you eliminate HTTP as a viable transport for SCADA because it is a stateless transport and bandwidth-heavy, MQTT emerges as a viable transport within the broad IIoT applications arena. In addition, MQTT was originally designed for VSAT SCADA infrastructure. It allows valuable VSAT space segments to be optimized for the number of remote sites within that space segment. Therefore, once an MQTT client session is established, total metadata overhead for messages is only three bytes. MQTT also takes full advantage of the underlying TCP/IP transport. That means MQTT is extremely lightweight and bandwidth-efficient on the wire, especially for VSAT and cellular network topologies. For factory-floor SCADA this can mean orders of magnitude reductions in network traffic. MQTT is now a global standard backed by several leading standards bodies including OASIS, ISO, and IEC.
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Arlen Nipper is president and chief technology officer at Cirrus Link Solutions.
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INFORMATION All Things MQTT: http://mqtt.org/ OASIS MQTT Standard: https://www.oasis-pen.org/ committees/tc_home.php?wg_abbrev=mqtt Eclipse Software Foundation: https://eclipse.org/ paho/ or https://iot.eclipse.org/ Node-RED: https://nodered.org/ Sparkplug MQTT SCADA Specification: https://github.com/Cirrus-Link/Sparkplug www.controleng.com/IIoT
CONNECTIVITY & COORDINATION: MANAGEMENT VIEWPOINT
The first three steps are always the hardest Accelerate the value of an IIoT strategy for enterprise assets
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The Industrial Internet of Things (IIoT) presents an opportunity for industrial companies to leverage existing data to improve operational excellence. Per Gartner, companies are responding–two-thirds of the respondents in a recent survey have either implemented or plan to implement an IIoT strategy. However, enterprises still face hurdles on how to adopt it. Concerns range from overcoming interoperability, avoiding high-cost implementations, and negotiating the risk of not achieving promised ROI. Fortunately, new best-practices are emerging that can help overcome these challenges, accelerate tangible benefits, and lay a foundation that will yield benefits for many years into the future. I have had the benefit of working with a few Schneider Electric software clients and have seen these deployments firsthand. Based on that experience, I found there are three cornerstones to an IIoT strategy that can help you to achieve success and usher in a new realm of innovation. To summarize, start small and work big–there are many tactical deployments of IIoT strategies that can be completed in a relatively short period. These may be tied to a specific component of your business–say a single line or machine that has been causing challenges. Pick a first project to demonstrate what options exist when ready access to the right data can be quickly attained, helping to make onwww.controleng.com/IIoT
FIGURE 1: Tata Power–one of the largest power companies in India–installed fleetwide predictive analytics, including at the Gujarat plant shown, where $270,000 was saved through early detection and identification of a circulation water pump blockage. (Courtesy Schneider Electric Software)
the-fly decisions to improve uptime, reduce loss, or improve quality. These micro projects can then demonstrate to senior management the viability of your IIoT project, which unlocks more funding and greater scope. The best long-term strategy is to envision an asset management program that covers all operations, across all sites. But executing that strategy can be a daunting task–hence a phased or tiered implementation program is ideal. The goal is an Enterprise Asset Performance Management (APM) solution–one that can integrate enterprise data collection, predictive analytics, comprehensive EAM and integrated workflow, among other capabilities, in a comprehensive openended package.
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To start your journey leverage as much existing infrastructure as possible. No one facility has a “pure,” single manufacturer equipment environment, so an open architecture is key.
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Let’s first look at how to get started. Here are three steps you can take today: Industrial Internet of Things
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CONNECTIVITY & COORDINATION: MANAGEMENT VIEWPOINT
FIGURE 2: A Carson City employee monitors asset performance and KPI data directly from his mobile device. (Courtesy Schneider Electric Software)
Build on existing investments The best way to start your journey is to leverage as much existing infrastructure as possible. When researching what future Enterprise APM solution you want to end up with, ensure it has an open architecture so it will operate seamlessly with your existing equipment, control layer, and data collection protocols. No one has a “pure,” single manufacturer equipment environment, so an open architecture is key. In fact, this realization simplifies what you decide to implement today, as it removes constraints imposed when limited to only choosing specific vendor solutions. And, given an operating environment is likely multi-vendor, it also makes implementing the foundation for future Enterprise APM simpler, as it does not require adoption of new equipment or sensors, letting you build on existing infrastructure. Users adopting Enterprise APM can see benefits no matter how simple or complex their current plant infrastructure. An organization without enterprisewide data collection
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The concepts associated with IIoT may seem unfamiliar, but real benefits have been
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capabilities will benefit from installing a data-management foundation to collect and contextualize information across their company. Those with an existing data-management foundation can readily add predictive analytics, unlocking further gains in their ability to foresee problems before they occur. Wherever your organization is in terms of your maintenance management maturity, plugging in value-added solutions to enhance the ROI of existing investments makes a lot of sense.
Leverage existing data for decision support
Industrial Internet of Things
An average plant can have over
8,000 data points from smart sensors on plant turbines, pumps, condensers, and other pieces of critical equipment. A modern utility may have more than two million data points across their generation fleet. But, without applying context or meaning to this data, it doesn’t do you any good, as it is just “white noise” in a loud environment. Here the winning strategy is to pick a few pilot projects where you know great information is hidden but are not leveraging it to your best ability. Simplifying the access route through user interfaces that point quickly to next steps can be a powerful way to empower employees, increase efficiency, and improve overall team performance. By implementing the data collection layer that will become part of your Enterprise APM solution, an organization can give engineers, supervisors, and executives key information quickly–and with greater accuracy and quality–which they can then have at their fingerprints to make better, faster, and more informed decisions. Plugging advanced analytic applications into the data-management foundation (by means of IoT-based connectivity) enables users to make sense of the increasing amount of data and discover actionable insights. Tata Power–one of the largest power companies in India–installed fleetwide predictive analytics and saved $270,000 through early detection and identification of a circulation water pump blockage.
Demonstrate real business value and results Adopting an IIoT strategy–executed through the implementation of an Enterprise APM solution–can have an immediate positive impact on the www.controleng.com/IIoT
Way to connectivity paved with good partners
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n late November, Schneider Electric announced its EcoStruxure architecture and platform as suitable for IoT-enabled solutions “at scale.” The architecture and platform connects core layers of the technology stack, from connected products to edge control, applications, analytics, and services. The company’s partners and end-users can develop scalable and converged IT/OT solutions for every level of an organization because the platform provides an IoT-enabled backbone for: Connectivity and intelligence for smart sensing, embedded computing, IP networking, and edge analytics; Foundation building blocks for smart control, management, automaton, and optimization; Infrastructure for digital services that enable cloud-based connected apps, analytics, services, control. and monitoring. Connectivity and data are used to create controls and attain actionable business insight using analytics. The resulting solutions allow customers and partners to augment their operations to raise efficiency, sustainability, asset performance and people productivity. The platform can foster open innovation and interoperability and is developed in partnership with leading standards organizations and best-in-class technology leaders.
bottom line of your business. Unlocking immediate access to missioncritical information lets organizations better predict issues before they occur. With this knowledge, it becomes possible to more effectively perform work order scheduling, optimize resource planning, and leverage existing operational data to maximize asset performance. Keep an eye on how you can bridge the information technology/ operations technology (IT/OT) gap to implement closed-loop business solutions. Improving the collaboration between your IT and operations team can have dramatic results. Using real-time data can then result in greater collaboration and continuous process improvement. This can lead to maintenance cost reduction, extended asset life, and ultimately, maximum economic return on assets. www.controleng.com/IIoT
Microsoft provides the Azure cloud platform for the delivery of Schneider Electric’s digital services, apps and analytics. It is the cloud backbone for EcoStruxure, easing technology development on the platform. The partnership enables Schneider Electric to rapidly scale public, private and hybrid cloud solutions. Schneider Electric uses Intel’s smart Field Programmable Gateway Arrays (FPGA) devices to power its sensors and devices, networks, and the Cloud. Intel’s FPGAs enhance the performance, power and flexibility of the EcoStruxure architecture to enable smarter operations. Other more recent partnerships include with specialized technology providers like Zuora and the company’s recently announced partnership with Panasonic, both of which enable delivery of technology, services, and business models. Schneider Electric also serves on the board of the Industrial Internet Consortium and Thread Group, where it is working with other leading organizations to accelerate the growth and development of IoT solution architectures and standards for the industrial and home automation industries. Schneider Electric is a global specialist in energy management and automation, with revenues of €27 billion in FY2015 and 160,000+ employees in over 100 countries.
Carson City achieved a 15% reduction in staff hours by implementing mobile reporting in their water/ wastewater infrastructure, optimizing operational visibility and readiness. Companies that have adhered to these three strategic objectives as part of their IIoT strategy–achieved in part, through an adoption of a Schneider Electric Enterprise APM platform–have gone on to experience significant business value, as validated through the following benefits: 30% reduction in maintenance costs 30% improvement in asset utilization 25% reduction in unplanned downtime 25% improvement in labor utilization 20% increase in asset availability.
While the concepts associated with IIoT may seem unfamiliar at first, there are real benefits that can be captured early on in your journey to becoming an IIoT-based organization. These advantages are available today, for industrial organizations that have the vision to first lay a foundation, and then build upon that vision through a journey to IIoT maturity made possible by harnessing these new capabilities. Leveraging an Enterprise APM strategy, companies can build on existing infrastructure, transform data into insights, and drive real business results. IIoT
Kim Custeau is director of asset management at Schneider Electric. Contact her at Kim.Custeau@ schneider-electric.com. Industrial Internet of Things
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CONNECTIVITY & COORDINATION: EXECUTIVE INTERVIEW
Out of the box Answers about IIoT for controls
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The recently introduced Industrial Internet Control System (IICS) from GE Automation and Controls is an out-of-thebox solution for applying the Internet of Things to heavy machinery and equipment in production plants and factories. Editors recently questioned Jim Walsh, president and CEO, and Rich Carpenter, general manager controls platforms, GE Automation & Controls, about its place in the Industrial Internet of Things (IIoT).
Q: How do customers use IIoT tools? CARPENTER: IIoT is enabling better asset performance management, with connectivity out-of-the-box, to help eliminate unplanned downtime. Predictive maintenance has been around a long time with GE software and services like SmartSignal. Now
advanced models run locally looking at the efficiency of a unit, know the related costs, provide information to operators, maintenance personnel and others, and advise when it is more profitable to do maintenance now, rather than let performance degrade. Use of models can improve performance from 5% to 15%. WALSH: One of biggest advantages we offer is that GE is one of largest equipment manufacturers on the planet, covering wind, power, transportation, oil and gas, and we know how to deliver solutions that drive meaningful outcomes. We’ve already proven the robustness of the proposition and the platform. The promise of IICS is a greater opportunity to help optimize how assets run, advancing productivity, and incorporating domain expertise into control systems with far more meaningful outcomes.
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Q: Can you give an example of how control systems could be more intelligent? CARPENTER: In water treatment plants, it’s expensive to move water from place to place. More intelligent control systems get the spot price of energy for that location, pull down the spot prices, and choose lowest cost, time of day to operate, saving well over a million dollars a year for one customer. In a utility boiler, if coal is moist, the control system should change the way the boiler is operating by changing the recipe of the burn to optimize performance. With gas turbines, there’s a tradeoff between profit and operating life of the turbine until shutdown maintenance is needed. By virtualizing performance, a customer can “bank hours” when the asset is not running at maximum, permitting the customer to overdrive the turbine as needed. Q: How is security addressed? CARPENTER: Most control systems try to use an air gap, but IICS has complete defense-in-depth with 23 points of security, so any threat doesn’t spread to other areas. Also, in communication with the cloud, if an application or firmware is different than expected, the system won’t allow it to run. The next level of communication is built into the communications stack; it’s ready for IEEE Time Sensitive Networks (TSN). Multi-stack controllers allow seamless upgrades when needed from a central location. IIoT www.controleng.com/IIoT
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