A growing number of technology vendors are offering cloud-based software for applications in automation, control, and instrumentation. Deciding where to install automation software remains the responsibility of the end user. For a given application, is it more helpful to "own" the software in the traditional way, or to adopt a Software as a Service (SaaS) or Platform as a Service (PaaS) approach?
Many industrial control systems (ICS) have been operating for 30 years or more with very few changes to their hardware or software. Because of the diverse media used in Ethernet applications, factory networks can potentially expose automation systems, whether in the cloud or on-site, to unauthorized access.
The rise of cloud computing
More and more manufacturers are exploring the potential of cloud computing (including Software as a Service (SaaS) and Platform as a Service (PaaS)) in the design and operation of industrial control systems. Key advantages associated with cloud computing include:
● The standardized development and testing simulation environment provided reduces the cost of building and configuring infrastructure.
● It allows for flexible use of distributed engineering resources, enabling multi-project and multi-user configurations regardless of geographical location.
● It allows for greater freedom to focus on the core capabilities of operating assets while reducing on-site physical space requirements, hardware, software, and maintenance.
● We can provide expertise to keep systems up-to-date and apply the right cybersecurity solutions to protect system security and intellectual property.
● A demand-driven pricing model invests only in applications that are actually needed, thereby reducing investment costs.
Growth of SaaS and PaaS services
SaaS is a software distribution model in which developers host applications and make those applications available to customers via the internet. Integrating SaaS into the process control domain means adding data collection, integration, and distribution capabilities beyond most existing systems.
SaaS extends access to factory data, enabling real-time monitoring of processes. It also provides the big data needed to drive predictive maintenance planning. It makes real-time key performance indicators and data dashboards visible across the factory or enterprise, allowing attention to be focused on more important aspects and fully leveraging the value of new or existing Supervisory Control and Data Acquisition (SCADA) systems.
When implemented correctly, SaaS can save significant costs compared to traditional software ownership methods. Even with redundancy and high availability, this cloud service model minimizes hardware and software setup costs, allowing for maintenance of running applications. End users do not need to manage or control IT infrastructure. Security, networking, computing, and licenses for all software are included in annual or monthly fees, eliminating or significantly reducing capital expenditures. Using any required service incurs a one-time cost. Businesses pay for what they use and have the flexibility to add or remove services as needed.
Another benefit of SaaS is the automation provided by the service provider, which typically includes updating software applications. The provider works with the customer to coordinate the installation of all installed software updates and patches as needed for the application, ensuring they function correctly. The provider takes on this responsibility because it helps customers use the latest software, reducing support costs while simultaneously improving security.
PaaS is ideal for industrial enterprises that develop and test software and database applications, providing a programming environment and developer tools. It offers a complete, centralized development environment that can be accessed on demand.
Certain cloud-based environments, including sophisticated simulation environments, allow for comprehensive testing of project applications before they are installed on production systems. Software and database applications can be custom applications that industrial enterprises have used in the past but are now deployed on virtual machines in the cloud. They can also be applications built from scratch in the cloud using platforms and tools provided by automation service providers.
In some cases, the same software can be used for both SaaS and PaaS applications. Control and process engineers can develop applications using a PaaS model and use SaaS for production environments. For example, automation, process control, and SCADA system software (previously installed only within customer plant facilities) can be developed offline and used with Open Virtual Engineering Platform (OpenVEP) or optimized SCADA software to provide enterprise-grade service reliability and security, enabling the monitoring and control of assets distributed across various locations.
Figure 1: The OpenVEP (Open Virtual Engineering Platform) provides an offline method for developing, testing, and validating existing ExperionPKS process control systems. It helps process or control engineers improve existing SCADA or control systems. Image source: Honeywell
Placing this type of software in a data center, with direct high-speed connections to telecommunications and the internet, enables high-speed, reliable connections to all remote devices and overall business visibility.
Cloud-based SCADA system
Traditional SCADA systems are fully owned, installed on-site, and require dedicated technical support personnel, resulting in relatively high capital and operating costs. These costs include security and firewalls, network equipment, and computer servers and software. However, on-site installation lacks flexibility and fails to effectively utilize valuable resources located elsewhere. More importantly, these on-site solutions may need to be updated every four to five years. Migrating existing solutions to new hardware is often more difficult than the initial installation—especially if virtualization was not implemented initially.
To help customers address operational and business challenges, leading automation vendors have developed SCADA software for managed cloud environments. These new cloud-based SCADA systems represent a software trend in the era of the Industrial Internet of Things (IIoT). Configuring functionality in the cloud means end users can shift from capital-based models to predictable capital and operating expenditure models. They can have a powerful SCADA system in their possession within days.
Figure 2: Automation and control systems must be more flexible and agile. Honeywell Process Solutions Experion Elevate is a process production system for remote SCADA, allowing users to monitor or control assets distributed across different areas.
Implementing cloud service strategy
Manufacturers must determine whether they should migrate some of their control and monitoring software to the cloud environment or retain it on-site. For companies with only one production site, implementing a cloud service model may not be necessary. However, manufacturers with multiple production facilities can leverage cloud services to collect data from different regions, enabling enterprise-wide data management and optimization. Some manufacturers may deploy it as a monitoring system to visualize the status of company priorities, thereby coordinating resources and making better enterprise-level decisions.
Traditional on-site installation offers advantages such as speed and simplicity, and eliminates the need for remote service license fees. Cloud hosting, on the other hand, allows for closer collaboration and access to control data anytime, anywhere, without the need to manage software licenses on a single computer. Employees can work from anywhere while still ensuring the security of their work within their responsibilities. Others can view the progress of specific projects to continue working on the current system.
The flexibility of using distributed engineering resources helps break down the barriers between experts in different fields. Businesses can significantly reduce travel costs while enabling remote work and faster time-to-market for new products. This also allows experts to support any factory facility, minimizing downtime while maintaining consistency across multiple facilities.
The choice between cloud and on-premises often depends on what is being controlled and where it is located. Employees increasingly need to coordinate within workflows rather than operating software alone on their own computers (which often lacks backups for critical programs). Manufacturers operating facilities in a specific region may want to host cloud-based solutions within that geographic area. However, if monitoring broader or globally distributed assets is required, a multi-cloud strategy may be necessary to allow for a smooth switchover to another location should one fail.
With the increasing prevalence of cloud computing, major automation vendors have begun offering both cloud-hosted and field control software. One reason for this is to comply with regulations and meet critical data requirements. Each approach has its own advantages and disadvantages.
Customers can partner with automation technology vendors to choose the right path based on their operational and business needs. The overall strategy may involve a hybrid solution. Relevant automation knowledge and experience are crucial for manufacturing companies to make optimal decisions.
Perhaps the greatest opportunity for cloud technology lies in remote monitoring of business operations. For example, if management wants to monitor the status of all factories and remote assets distributed across different regions, they can use a SaaS cloud solution. This approach provides a set of dashboards, key performance indicators, and other reporting capabilities to help understand the overall state of the enterprise. It enables a consistent understanding of the current situation and aggregates data from hundreds or thousands of facilities, presenting it in visual graphs, thereby attracting the attention of stakeholders across the enterprise and helping them make better decisions.
Figure 3: Honeywell’s PaaS is accessible anywhere, on any version, configuration and size of automated system, and provides security, firewall, networking and licensing to reduce architecture, hardware and software purchases and maintenance.
Layered cybersecurity strategy
Hosting industrial plant environmental data to the cloud raises security concerns, prompting major technology vendors to deploy robust defense-in-depth strategies. This involves deep protection of software through multiple layers of physical and cybersecurity. This gives security experts time to identify and mitigate intrusions before they impact critical control assets.
In addition, flexible solutions incorporating additional firewalls and advanced encryption can be developed to enhance security by maintaining secure access to the client's control infrastructure and intellectual property.
Industrial companies can now use the same software (whether on-site or in the cloud) to realize the benefits of their control or automation applications. Cloud service models offer significant advantages for collaboration and mobile access, but end-users must consider their specific requirements when selecting control software or platform approaches.
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