Throughout history, industrial revolutions have hinged on the power to automate processes. While automation today offers many benefits, imagine if you could automate thousands – or even millions – of processes simultaneously? This is the next potential wave of innovation, and it’s the organizations that are “geographically dispersed” or “automation heavy” that will benefit the most.
While long-range communications and connectivity have become increasingly easier to attain, businesses need to be able to break down their isolated islands of automation to achieve comprehensive and connected automation at scale. For example, there always has been a clear line dividing operations technology (OT) and information technology (IT) networks. The emergence of the Internet of Things (IoT) blurs that line as industrial operations head in the direction of complete connectivity for all devices on a network – including those remotely located in the field. With new dedicated access layer platforms, IoT data can be analyzed, acted upon and transmitted from anywhere in an Industrial IoT (IIoT) network.
The increasing shift toward IIoT tends to bring up a lot of questions about the continued value of Supervisory Control and Data Acquisition (SCADA) systems that have traditionally served as the driver for monitoring and control in industrial markets. Although OT and IT are beginning to converge, there is still high demand for SCADA data. However, new technology offers the opportunity for data to be used in ways that were previously not possible, such as predictive analytics. This doesn’t make SCADA obsolete, as many operators are using it and will continue to use it. But industries may start seeing new technology added to the network to support intelligent data transmission.
Sensor-2-Server (S2S) intelligent communications for the access layer can collect and transport the data that supports higher-level analytics. As IoT becomes adopted by industrial markets, there is going to be an increased demand for sensor data from the outermost layer of the network (think sensors on oil pads or water tanks). Industries like oil and gas, electric power, agriculture and utilities, are starting to pick up on the benefits of S2S when it comes to profitability and cost savings through more advanced data analytics.
Defining Sensor-2-Server
S2S is intelligent communication that begins at the sensor level and targets servers for specific reasons. These servers could include anything from a SCADA data server that collects and monitors through the SCADA system or a Big Data engine. S2S could be leveraged in a predictive analytics environment or server farm that compares data at rest to data in motion at the access layer of the network. The concept of S2S extends beyond transmitting data. It is about creating intelligent transmission from a specific location back to the appropriate server with the appropriate intelligence to drive action for change.
What is the access layer?
The access layer is the edge of the IT network. An IT infrastructure has a core that is home to all the big data and data analytics. At this core, the data is at rest because it has reached its final destination. Next is the distribution layer of the IT infrastructure which is where the major plants, sites and facilities are located. Further out is the aggregate layer where data at the next level in the network is collected. Extending out even further is the access layer.
In oil and gas, for example, an oil pad would be part of the access layer because they are typically remotely located at the edge of the network. It is highly likely that sensors physically exist in this layer for monitoring and control of these devices. Additional examples of the access layer are tanks, refinery sites and ocean exploration vessels. In water/wastewater, the access layer could be the treatment facility that has the water meters, pumps, etc. Essentially, in an industrial site, the S2S access layer is the furthest point at which the operators are collecting sensor data. Industrial organizations today need intelligent secure communication and transmission from the sensor data back to the appropriate server, and there are a number of available options.
Implementation of S2S Communication
When implementing S2S networks, the operator needs to have a solid understanding of the following:
- What sensor data do I want to collect?
- What does the architecture look like?
- Where does the data need to come from and where does it need to go? For example, is it just going to SCADA or is it going to other data sources?
These key details will drive the selection of the technology that best fits, in addition to the physical environment where it needs to transmit data. Carefully selecting the right pieces will help in architecting the network. In order to make S2S work, an operator needs to understand the physical environment needs. Everything is unique when it comes to RF in particular, and an operator must fully understand their environment if they want to be successful. The ability to collect the data is the first step in improving intelligence of Sensor-2-Server communication, which starts with technology selection.
The Four Tenets of Sensor-2-Server
To establish the most effective S2S communications network, there are four core tenets that the technology must support: collecting the data, protecting the data, transmitting the data and controlling the data.
Collect
The technology must allow the operator to collect data from any sensor – whether the sensors are analog or digital, wireless or wired. In some instances, the technology may need the extended ability to collect data at the access layer in a data logging fashion – allowing the operator to collect it, store it locally and make it available to SCADA systems.
Protect
The intelligent communication must be able to protect the network against cyber-attacks. It must fix the boundary between the sensor and backbone network. Without ample security in the environment, many industries can be at risk for severe consequences such as compromised data or denial of service.
Transport
The data must be transported to the appropriate location for analysis, no matter where the data is collected from. Operators should look for a system that offers seamless wireless data connectivity from Sensor-2-Server.
Control
The Sensor-2-Server technology must add intelligence to the access layer. Data logging is critical, and operators must have the capability to pull data in and control what happens with the data, where that data is stored, and users can leverage that data at the local level or back at the core network.
Benefits of Intelligent Sensor-2-Server Communication
S2S technology can be effectively deployed in the energy sector, whether it is oil and gas, electric power, solar, wind and or tide-based energy. Additionally, utilities, precision agriculture and irrigation can also benefit from intelligent S2S communication. With an intelligent communication system, operators can leverage new technology to improve the profitability of their businesses in ways previously considered impossible. For example, if an oil and gas company can use predictive analytics to estimate the price per barrel, the company can be more responsive - in real time - on its oil production levels. The data gathered from predictive analytics can help operators determine if production should be increased or decreased in certain areas, thus driving higher profitability. These technologies can also lead to cost reduction. For example, by deploying S2S technology at the oil well, the operator does not have to send as many workers out in the field to manually collect data. By enabling multiple benefits (profitability and cost reduction), S2S offers a value proposition that is getting the attention of many industrial operators.
From a technology partnership perspective, Big Data vendors face the challenge of comparing data in motion versus data at rest. If the data has already moved through a SCADA system and has been aggregated, changed, stalled, or is not quite granular enough, it can be difficult to achieve predictive analytics. The concept of predictive analytics is that an operator can make an accurate estimate that certain things can happen during operations. However, the operator needs to determine what the drivers are for the predicted actions to happen and must look at active data to determine if this is, in fact, happening. Without insight into the active data in motion, they are lacking an essential piece of the predictive analytics. This ability to compare data in motion at the access layer could benefit Big Data vendors when it comes to predictive analytics because it allows them to give higher value to their customers, which drives additional revenue. With S2S technology, they can deploy a tiered application infrastructure that allows data to intelligently move from one point to another.
S2S also enables operators to go beyond a legacy SCADA data network. To operate a SCADA network, it requires a lot of institutional knowledge to truly understand, manage and work within the environment. S2S expands beyond moving the data into SCADA systems and allows operators to leverage more advanced technology, like predictive analytics. Essentially, S2S communications provide the opportunity to take advantage of new advanced tools, but the operator doesn’t necessarily have to sacrifice the institutional knowledge built into the SCADA data systems.
As new generations enter the workforce, it’s likely that there will be a shift and some of that institutional knowledge will be replaced with technology that will allow operators to do more than they ever could before. The addition of new technology and IoT networks is where operators are starting to see a closer line between the IT and production groups. As more technology is leveraged, these two disparate groups will have to work together more often. There is now a drive for a more holistic picture of what is going on in IT, what is going on in the field, and whether the technology used will be compatible with future needs. SCADA will likely always have value for industrial communications but, going forward, there will be an increase in the use other technologies as well. Additionally, with more technology physically in the field, there is always going to be a focus on data security.
Data Security
Sensors at the access layer present interesting security challenges. For example, consider a data concentrator sitting on an oil pad that is collecting data. This device is collecting data from a number of sensors and has data logging capabilities, which also means the other devices sitting at the remote site contain historic data. Technology providers need to insure that the technology used is taking advantage of all the security features that are available to make sure their data is protected through a variety of means including encryption, authentication, virus and intrusion protection, and by being physically tamperproof.
With the growing interest in IIoT, the system is providing a communication path with highly valuable information. These sensors may be running an application on the edge of the network, and many of these devices are using IP. When there are Ethernet and IP devices going out to edge devices in the field, each one of those devices has the potential to become a threat to the entire corporate network if they’re not secure. Operators in IIoT environments need to be concerned with everything that could be introduced to the network at every single connection point. Data protection data is a fundamental and extremely important element in determining the effectiveness of S2S communication. Technology vendors must be mindful of security in every step of the design and installation process, and operators must require security features that will protect their data and networks.
Conclusion
Industrial communication is changing in the sense that IIoT enables the possibility for every device in a network to be connected – including those in the outer access layer. This has created a convergence of OT and IT operations in many instances or - at the very least - has brought the two departments to a closer working capacity. IoT and technology at the access layer enable the option for Sensor-2-Server, a form of intelligent communications that can move the sensor data to a specific server for detailed analysis. New data and technology is allowing operators to do things they’ve never done before, such as predictive analytics. As this shift continues, SCADA is not being becoming an obsolete technology; rather it will become a piece in the bigger technology picture. Any operator choosing S2S technology, or any technology for that matter, must carefully consider the options and keep security as a top priority.
Edited by
Ken Briodagh
