Care of: IT (Information Technology) Department

SUPERVISOR SYSTEM
Technical Specifications

Date: April 27, 2018

Revision: 7.5
Changes made: Modified technical details about SPLT

Authors: Federico Milan, Ivan Citton

Abstract
System Platform supervision structure and specification for Breton plants with supply
requirements.

Specifications
Milan.federico@breton.it
Citton.ivan@breton.it
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CONTENTS

Table of Contents
INTRODUCTION ................................................................................................................................................. 2
PURPOSE ........................................................................................................................................................ 2
BRETON SUPPLY......................................................................................................................................... 2
TO BE SUPPLIED BY THE CLIENT ................................................................................................................ 3
VALIDITY ........................................................................................................................................................ 4
ASSUMPTIONS AND DEPENDENCIES ................................................................................................................. 4
GLOSSARY ...................................................................................................................................................... 5
REFERENCES................................................................................................................................................... 5
INTRODUCTION ................................................................................................................................................. 7
WHY SYSTEM PLATFORM? ............................................................................................................................ 7
ARCHITECTURE .................................................................................................................................................. 8
SUPERVISION SOFTWARE AND REMOTE ASSISTANCE .................................................................................. 8
PANEL PC ................................................................................................................................................... 8
SUPERVISION SYSTEM ............................................................................................................................... 8
PROCESS DATA LOGGING ........................................................................................................................ 12
BRETON SOFTWARE MODULES ............................................................................................................... 13
IMPLEMENTATION OF THE SOLUTION ............................................................................................................ 14
CUSTOMER SYSTEM REQUIREMENTS.............................................................................................................. 15
CUSTOMER SYSTEM REQUIREMENTS.......................................................................................................... 15
PC SERVER................................................................................................................................................ 15
SERVER ROOM ......................................................................................................................................... 17
NETWORK INFRASTRUCTURE .................................................................................................................. 17

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INTRODUCTION
Plant supervision is based on ArchestrA Wonderware System Platform technology. Commissioning and
exploitation of the graphic interfaces calls for compliance with several requirements in order to guarantee
the security, performance and robustness of the developed applications.

The supervision system, based on ArchestrA System Platform technology, is articulated on four Windows
Servers and it employs the MS SQL Server database. To guarantee scalability and security, the environment
is implemented in a virtualization system based on VMware technology.

The choice of VMware is based on the fact that almost all Breton clients that manage plants are equipped
with a Data Centre running VMware technology.

PURPOSE
The purpose is to identify the products and services supplied by Breton and those to be supplied and
prepared by the customer, and, where possible, to provide information of a technical nature able to maximize
performance and security.

BRETON SUPPLY
The Breton supply can be summarised in the following 3 points:

1. The plant supervision application developed in System Platform (assisted by any modules developed
by Breton in the languages and technologies chosen by Breton).
2. User licenses for System Platform and the MS SQL database for the use of Wonderware.
3. The touch screen PCs on board the machine (HMI).

Plant supervision application

The supervision application has a back-end facing the PLCs and a graphic front-end facing the operator (HMI).
The back-end can use Historian technology to record the process data defined as of interest by Breton or by
any requests of the customer prior to definition. These data are consulted using the tools provided by System
Platform (Client Historian). The graphic front-end created with ArchestrA technology is designed to replace
legacy HMI technologies and provide:

1. Machine status information for the operator

2. Details of any fault conditions
3. Control of zone states (automatic, manual, semi-automatic)
4. Control of machine parameters

Certain plant types may include modules that can be interfaced with the supervision system to allow the
following data to be saved:

1. Raw materials used

2. Product manufactured
3. Formulation data
4. Any machine data considered sensitive or of interest

No reporting tools are supplied in terms of software for printing or production of the data in digital formats
(pdf, …). If necessary, interfaces will be provided for the field display of the data of interest (e.g.: number of
slabs produced, slab weight, etc.).Due to its nature of being intrinsically connected to the requirements and
policies of the client, reporting is deferred to the customer; Breton provides support – on request – in relation
to methods for retrieving any final data available.

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TO BE SUPPLIED BY THE CLIENT

The supervision application calls for the use of multiple servers. Physical machines require preventive and
corrective maintenance, although this may be in conflict with the need to keep the supervision system
available at all times. To obtain the maximum availability of the supervision machines the server machines
are configured using virtualization technology in order to optimize the physical machines. Installing multiple
physical machines produces hardware redundancy and makes it possible to service the machines without
impacting the supervision system.
Note that supervisor application is a SCADA and HMI software so it has a key role in managing plant.
Therefore virtual machines that host supervisor system have to be available 24 hours per 7 days during work.

Breton does not supply physical and virtual server machines. The customer is responsible for maintaining
and managing the server machines.

The customer must therefore supply:

1. Pc Server and server room

a. A suitable room to accommodate the PC servers.
b. Pc Server
i. Physical host (with DVD player available in virtual machines)
ii. Virtual machines (below details).
c. Continuity of the electrical power supply and cooling system must be assured for the servers.
Moreover, the server room must not be subject to any kind of vibration.
2. The network infrastructure required to connect the supervision servers to:
a. All the plant PLCs or anyway PLCs involved in the supervision system.
b. All the machine on-board consoles on which the Wonderware runs.
c. All the plant consoles that need to exchange data with the supervision servers.
Note: The network infrastructure dedicated to the supervision system must be separate from the
office network.
See Breton specific document about network requirements.

Hardware requirements of PC Server can be summarized in:

1. Have sufficient PC server to virtualize server requires the execution of PC System Platform
2. Have enough processing power to ensure performance during normal operation and to ensure the usability
of the system in the face of anomalous or service.

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VALIDITY
The specification is applicable to all plants and machines with System Platform, with the exception of any
minimal revamping of systems after prior discussion with the related analysis of pros and cons.

ASSUMPTIONS AND DEPENDENCIES

The servers (physical and virtual) are owned by the customer who must ensure the retention and security of
data, in compliance with standards.

It is assumed that the customer has an IT structure (or IT consultants) capable of supporting the
commissioning of the supervision system and responsible for servicing the installed servers for the
supervision system (i.e. all the machines running the client's commands and controls and containing know
how data).

It is assumed that the communication network between PLCs, PCs and Servers is constructed in accordance
with best practices and in compliance with the applicable legislation in the country in which the plant is
located.

The supervision software and its performance are dependent also on the structure provided by the customer.

Breton will supply these guidelines, the physical and virtual machines, and any support required for the
supervision software. Maintenance of the installed machines and related databases is the responsibility of
the customer, i.e. the proprietor of the know-how is responsible for guaranteeing its efficacy either directly
or through third-party consultants.

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GLOSSARY

1. Wonderware
Wonderware is the global leader in Human Machine Interface (HMI), SCADA and real-time operations management
software. Wonderware solutions enable production and industrial operations to synchronize with business objectives to
achieve speed, flexibility and sustained profitability. Wonderware software delivers significant cost benefits for designing,
building, deploying and maintaining robust applications for manufacturing and infrastructure operations. System Platform
2. ArchestrA
ArchestrA is a comprehensive automation and information software architecture designed to integrate and extend the life
of legacy systems by leveraging the latest, open industry standards and software technologies. It also unifies the Invensys
products that make up the InFusion Enterprise Control System. ArchestrA ‘industrializes’ Microsoft .NET and other
Microsoft technologies in order to provide an even more productive toolset for building critical operations management
software solutions for manufacturing, production and facilities operations. The result exposes services needed by
manufacturing and industrial infrastructure such as common name space, object management, industrial security, high
availability and redundancy, plant connection, enterprise connection, client interface, web portal, workflow, and systems
management.
3. System Platform
Wonderware software is based on a distinctly unique, powerful and elegant approach to delivering what customers most
need in their real-time industrial software systems. Wonderware System Platform surpasses all other platforms in
engineering simplicity, operational agility and information empowerment. It helps customers secure their future, protect
the operational integrity of their plants, enhance the operational insight of their people and enables them to adapt easily
and affordably to change. These are a few of the are many reasons Wonderware software is the world’s favorite and brings
value to thousands of organizations.
4. VMware
VMware, Inc. is a US company that provides cloud and virtualization software and services,[2][3][4] and claims to be the first
to commercially successfully virtualize the x86 architecture.[5] Founded in 1998, VMware is based in Palo Alto, California. In
2004 it was acquired by and became a subsidiary of EMC Corporation, then on August 14, 2007, EMC sold 15% of the
company in a New York Stock Exchange IPO. The company trades under the symbol VMW
5. Revamping
Restructuring/refurbishment of the original software on new hardware
6. ASEM
http://www.asem.it/en/profile/
7. Server Machines
Phisical computer on which that program runs, that provides a specific kind of service to client software running on the
same computer or other computers on a network.
8. HMI
HMI stands for Human-Machine Interface, i.e., it allows for interactions between human operators and machines.
9. LAN
A local-area network (LAN) is a computer network that spans a relatively small area. Most often, a LAN is confined to a
single room, building or group of buildings, however, one LAN can be connected to other LANs over any distance via
telephone lines and radio waves.
10. WAN
A wide area network (WAN) is a telecommunications network or computer network that extends over a large geographical
distance. Wide area networks are often established with leased telecommunication circuits.
11. PLC
A PROGRAMMABLE LOGIC CONTROLLER (PLC) is an industrial computer control system that continuously monitors the
state of input devices and makes decisions based upon a custom program to control the state of output devices.

REFERENCES
The specification refers to System Platform 2014 or higher, Windows Server operating system, and VMware
virtualization system.

For specifications of the products listed refer to the related websites:

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 System Platform
http://software.schneider-electric.com/products/wonderware/hmi-and-supervisory-control/system-platform/
 Windows server
http://www.microsoft.com/
 VMware
http://www.vmware.com/

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INTRODUCTION
The main aspects of the supervision system can be summarised as follows:

1. Stability and durability of the product

a. Use of virtualization technology
b. Functional assistance, also remote
c. Make the customer's IT department autonomous in relation to maintenance of the pc
servers
2. New paradigm of usability for the user interface
a. Global control of the plant
b. Several access levels (2 for the customer)
c. Single graphic interface for on-board machine and the control room (if any)
d. Modular construction of the graphic interface
3. Improve perception of plant status
a. Option to access the user interface from all consoles on the plant
b. Display the interface also in other environments or locations
4. Log the process data deemed to be of interest.

WHY SYSTEM PLATFORM?

Since 2010 Wonderware System Platform has been the standard plant supervision system for Breton SpA.
System Platform is a technologically innovative and constantly updated product; it is compatible with the
PLCs controlling Breton plants and with emerging digital technology.

Wonderware holds a 40% share in the supervision market, so continuous and enduring support is
guaranteed; no less important is the constant development of versions aimed at optimising performance and
offering new functions.

Virtualization systems support makes it possible to maximize availability and robustness, deferring
complexities to fully consolidated IT structures, which endows the customer system with the optimal level of
independence in respect of preventive and corrective plant maintenance requirements.

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ARCHITECTURE
The supervision software architecture is modular and based on the concept of distribution, which makes it
necessary to use multiple machines.

SUPERVISION SOFTWARE AND REMOTE ASSISTANCE

The Breton supply comprises

1. PC panel for local machine control functions

a. Ubiquity platform for remote assistance
2. System Platform Application
a. Supervision on HMI for machine control and command functions
b. Logging of process data deemed to be of interest using HISTORIAN
c. Management modules: raw materials, formulas management, materials final inventory
3. System Platform License

PANEL PC
Control desks with ASEM PCs are installed on board the machine. The supervision system is not installed on
the ASEM PCs, which are connected to the supervision server (TSE) by means of the Remote Desktop
application. The ASEM PCs can be equipped with applications or modules developed by Breton to handle
special local functional requirements.

The ASEM PCs are already equipped with a Ubiquity license for remote assistance purposes.

The ASEM PCs feature 2 Ethernet ports designated:

 LAN: communication port for supervision system or machine systems

 WAN: dedicated port for secure Internet connection; this port is used for the remote assistance
service using Ubiquity platform technology

Any remote assistance required must be arranged with the after-sales service.

An ASEM PC has a high MTBF value, however attention was also paid to ensuring availability of each ASEM
PC by implementing architecture that allows rapid management of the various faults that may arise during
normal production. The use of the TSE server increases overall security because if the panel should develop
a fault, no further installation is required: simply remove the faulty PC and replace it with a new one, ensuring
you retain the same computer name.

SUPERVISION SYSTEM
From a software perspective, the supervision is conducted on a Windows Server machine designated TSE
(the machine is parametrised as Remote Desktop services). The TSE machine is accessed from the ASEM PCs
using Remote Desktop.

The graphic application manages interaction with the operator and provides the control and command
interface. The interface is designed so that the operators can interact with it using a touch screen.

To interact with the interface (surf the pages, edit values, etc.) the operator must log into the system by
entering his/her access credentials. The system tracks logins on allowing checks to be performed on who is
currently connected and also providing the facility to subdivide users into the following three groups:

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1. Operators
Operators can interact with all the data required to maintain product quality and plant productivity
in NORMAL conditions
2. Supervisors
Supervisors can interact with reserved data.
They can interact with all the data required to CHANGE the characteristics and productivity of the
plant or such that may be required to RESTORE normal operation of the machine.
3. Administrator
Administrators are Breton technicians or the customer's suitably trained maintenance personnel.
Administrators can interact with all the data that are required to PRESERVE mechanical functionality
or to CONFIGURE machine operations.

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The entire plant can be displayed from any single console. Specifically, the screen pages are divided into
coherent areas in the form of a tree structure. The operator can find the information required quickly by
following the path shown by the macro buttons that provide a visual indication of their functions.

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PROCESS DATA LOGGING

System Platform is able to log process data; this function is implemented at the time of commissioning of the
supervision system or in response to a specific request. System Platform is equipped with a tool to display
saved data and export them or conduct post-processing operations (e.g. comparison).

The data saved with these tools are numerical values recorded in the form "Parameter" vs "Time".

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BRETON SOFTWARE MODULES

Depending on the type of plant, modules can be supplied for the management of raw materials, saving
formulas or displaying the quantities of slabs produced

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IMPLEMENTATION OF THE SOLUTION

The new supervision management system was created due to the need to meet the customer's need to be
able to perceive and understand the production process, adapt to new structural requirements – also of the
customer's IT, make it possible to offer remote assistance, and provide a complete overview of plant
management.

1. Stability and durability of the product

a. Use of virtualization technology
b. Functional assistance, also remote
c. Make the customer's IT department autonomous in relation to maintenance of the
machines

Created using VMware infrastructure, Ubiquity platform, management of the machines and
network deferred to the customer

2. New paradigm of usability for the user interface

a. Global control of the plant
b. Several access levels (2 for the customer)
c. Single graphic interface for on-board machine and the control room (if any)
d. Modular construction of the graphic interface

Created with the framework developed since 2010.

3. Improve perception of plant status

a. Option to access the user interface from all consoles on the plant
b. Display the interface also in other environments or locations

Implemented by incorporating Situational awareness

4. Log the process data deemed to be of interest.

Implemented using HISTORIAN

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CUSTOMER SYSTEM REQUIREMENTS

The supervision architecture uses System Platform is based on Windows Server machines and specifically the
VMware virtualization environment, which makes it possible to guarantee higher reliability of the entire
system. The virtual machines are implemented on the physical PC servers. To guarantee availability and
performance PC servers have to satisfy some specifications.

CUSTOMER SYSTEM REQUIREMENTS

The customer must provide the following servers and infrastructure:

1. Pc server and server room

a. Physical pc server.
b. Virtual machines.
c. Storage San
d. Licensing (OS and wmWare)
e. Server room.
2. Network infrastructure: See Breton specific document about network requirements.

PC SERVER
The customer has to provide physical pc server to host the virtual machines in which will be installed the
System Platform application.

Note: Physical PC servers have to belong to wmWare compatibility list.

Physical PC server
In order to provide the correct availability of the system and have sufficient performance below is provided
a possible configuration that optimizes cost and performance. Breton strongly recommend to provide
performance equivalent to the hypothesis here:

 2 PC server like HP DL380 Gen10 with

o 2 processor for each physical server with
 12 core or more for each processor
 Frequency ≥ 2.4 GHz
o 64 GByte RAM
 To do easy maintenance
 To be more reliable
 SAN/NAS Storage with at least 3Tera Byte. We suggest using RAID technology for redundancy.
o HD with 10K or 15k rpm for virtual machines operating system and data storage
o At least 1100 IOps needed.
o Interface between physical host and storage with SAS 12G or fiber channel. Please do not
use I-SCSI interface.

 UPS system to avoid suddenly server powering off.

Virtual server machines

Virtualization environment: use wmWare Essential plus 6.0 version. Do not use Essential license. Essential
PLUS allows important feature as HA and Vmotion. These features are important for reliability and
maintenance.

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Supervisor need virtual machines with Windows 2012 R2 Server defined as follows:

 GRNODE
o OS Windows 2012 R2
o 8 processors
o 20 GByte RAM
o Disk C :100GByte (OS)
o Disk E: 1TByte for storage and applications.
o (optional) Disk F 500 GByte for DB logs.
o Disk S: Swap Disk
 AOS1
o OS Windows 2012 R2
o 6 processors
o 6 GByte RAM
o Disk C :100GByte (OS)
o Disk S: Swap Disk
 AOS2
o OS Windows 2012 R2
o 6 processors
o 6 GByte RAM
o Disk C :100GByte (OS)
o Disk S: Swap Disk

 TSE1
o OS Windows 2012 R2 configured as Remote Desktop Session Host
o RSD licensing depends on HMI control panel number (RDS CAL PerUser):
3X RDS CAL =15 contemporary connections
o 16 processors
o 48 GByte RAM
o Disk C :100GByte (OS)
o Disk E :100GByte (Data)
o Disk S: Swap Disk

Windows Settings

 Each Virtual Machine has to be in Application Server Mode. None of these can be a Domain
Controller. Virtual machines have to belong to a Domain. This is necessary to manage correctly
PerUser license in TSE1 (See below).
We strongly recommend to create a dedicated domain for production line.
 Virtual machines are not allowed to connect internet.
 Disable windows firewall or add exception to allow remote desktop connections.
 Disable windows update.
 Antivirus: if you use it, you need to request Breton exclusion list to be supervisor system compliant.
 UAC: Disable UAC (User account control).
 Region: Set English (UK) format. The dot has to be decimal separator.
 Users: Create for each virtual machines two users in “administrators”. Username:buser1
Password:Breton01; Username:buser2 Password:Breton01;

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 Install Acrobat Reader in each virtual machines.

 Synchronize and keep synchronize date and clock in VM
 For GRNODE:
o Install .net 4.5 and .net 3.5 features and handwriting recognition features.
 For TSE1:
o Install RDSH role (Remote desktop session host) and its licenses (Per user license).
o Install .net 4.5 and .net 3.5 and handwriting recognition features.

Storage SAN/NAS
SAN/NAS has to be compatible with the physical machines. It suggests a device with dual power supply and
dual controller. Supervision performance deals with SAN/NAS performance.

VIRTUAL MACHINES DEPLOY

To maximize the performance, the virtual machines are deployed on physical pc server in this way (in the
case of physical and virtual machines described above):

 Physical server/Host 1
In this case host 1 uses 20 processors on a total of 24 and 32 GByte Ram
o GR Node
o AOS 1
o AOS 2
 Physical server/Host 2
In this case host 2 uses 16 processors on a total of 24 and 48 GByte Ram
o TSE 1

The network links between different physical host have to be made using adequate network and due
privileges.

SERVER ROOM
The server room must be able to ensure service continuity of the servers. Continuity of the electrical power
supply and cooling system must be assured for the servers. Moreover, the server room must not be subject
to any kind of vibration. In relation to this requirement, it is important to ensure the server room is
sufficiently removed from vibration-generating equipment.

NETWORK INFRASTRUCTURE
See Breton specific document about network requirements.

Specifications | SYSTEM PLATFORM