HRTC Hard Real-time CORBA IST 37652 WP4 / Viena September 11-13, 2002 1 Process Control Testbed Manuel Rodríguez Santos Galán Universidad Politécnica de

WP4 / Viena September 11-13, 2002

1

HRTC

Hard Real-time CORBA

IST 37652

Process Control TestbedProcess Control Testbed

Manuel RodríguezSantos Galán

Universidad Politécnica de Madrid

WP4 / Viena September 11-13, 2002 2

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IST 37652Hard Real-time CORBA

OutlineOutline

Process Industry Control Manufacturers Process Control Testbed


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Process IndustryProcess Industry

Refining Power Chemical Pharmaceutical Cement Food Plastics Water & Waste


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Cementprocess

Ethyleneprocess


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Process control levelsProcess control levels


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.Distributed Control SystemDistributed Control System

Traditional approach


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Control ManufacturersControl Manufacturers


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)Emerson (Fisher-Rosemount) Emerson (Fisher-Rosemount)

PlantWeb PlantWeb PlantWeb field-based architecture is an automation solution that delivers

asset management, process control and management execution through three key components:

• Intelligent field devices • Standards & platforms • Integrated modular software

These networked components are linked by open communication standards that include FOUNDATION™ fieldbus at the field level, Ethernet at the plant level, and OPC at the supervisory level.

In such a solution, all components act as nodes on the network, collecting, distributing and using information.

In the simplest interpretation, PlantWeb works like this:• Intelligent field devices gather information • Delta V™ automation system provides easy management • and delivery of the information for process control and management execution

functions • AMS software processes the information to add asset management functionality


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DeltaVDeltaV

Several fieldbuses integrationFieldbus,Profibus,HART...

The Control Network isan ethernet network.

Incorporates OPC for integrationwith business applications


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Honeywell PlantscapeHoneywell Plantscape Its advanced architecture encompasses a high-performance

controller, advanced engineering tools, and an open control network. PlantScape makes use of the latest technology that includes:

• a powerful Microsoft Windows 2000-based Server with dynamic data caching, alarming, human/machine interface, history collection, and reporting functions;

• HMIWeb™ Technology, providing secure, advanced user interface HMI capabilities based on an open industry standard html file format and Web Browser access;

• a compact Hybrid Controller that provides truly integrated control;• object-oriented tools to quickly and easily build reusable control

strategies;• ControlNet, an open, state-of-the-art producer/consumer control

network;• FOUNDATION Fieldbus, for integration of measurement and control

devices; and• secure Internet Browser based on-line documentation and support.


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Invensys (Foxboro)Invensys (Foxboro)I/A Series SystemI/A Series System A hierarchical perspective, ranging from

enterprise-wide information protocols down to the instrument bus.

• Enterprise information: generally Ethernet/ TCP/IP

• Control bus: Ethernet/TCP/IP is now the standard.

• The I/A Series incorporated the first Ethernet control bus (Nodebus – Redundant).

• Redundant fieldbus to remote I/O.• Instrument bus: Intelligent field device

integration (for example, HART, FOUNDATION fieldbus, Profibus, FoxCom). Invensys/Foxboro introduced the first all-digital intelligent instrument bus.


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As Ethernet becomes the dominant communications structure, the traditional hierarchical nature of these four layers becomes less important, and we see the overall architecture

flattening.


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Jamnagar refinery (India) network (largest process control and information network in the world):256 operator consoles,26 safety systems,8000 intelligent transmitters, 40000 hard-wired signalsand 180000 signals from serial inputs


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Yokogawa STARDOMYokogawa STARDOM


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Trends in Process ControlTrends in Process Control

Information integration. Information availability throughout the system Safety management (alarms, sequence of

events) Real time databases Redundancy (networks and controllers) Hot swapping “Easy of use” Reconfigurability


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Network FeaturesNetwork Features

Traditional hierarchy is flatening Three main networks:

Field network (uses one of available fieldbus protocols)

Control network (usually propietary and usually an Ethernet network.

Information network: Ethernet network. “Openness”


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Process Control TestbedProcess Control Testbed

The HRTC Contract• composability in heterogeneous process

control applications


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PCT ObjectivesPCT Objectives

Identify requirements for CORBA-based distributed control systems.

Perform experiments in conditions of systems heterogeneity and legacy integration.

The PCT will be:• Representative of an industrial process plant.• Able to prove different design alternatives to the

normal industrial approach (such as different topologies, integration of heterogeneous devices at the same level,...)


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PCT ScenariosPCT Scenarios

Heterogeneity• Interoperation of heterogeneous subsystems

Scalability• Addressing large process control

Dependability• Reliability• Availability• Maintainability


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Scenario 1: HeterogeneityScenario 1: Heterogeneity

Phases: engineering+operation+maintenance

Develop a process control application that integrates an heterogeneous set of components

Record development and maintenance integrational issues

Test real-time operation


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Scenario 1Scenario 1

PROCESSPROCESS

TDC3000TDC3000DatabaseDatabase

SensorSensor ActuatorActuator

ControllerControllerGUIGUISimulatorSimulator


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Scenario 2: ScalabilityScenario 2: Scalability

Phases: engineering+operation Develop a process control application that

can grow in number of components Record development problems Test real-time operation as numbers grow Test real-time operation as topology

changes to overcome limitations


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Scenario 2.1Scenario 2.1

DCS

Simulator HMI

RT-DB

ORB

Plant


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Scenario 2.2Scenario 2.2

PROCESSPROCESSTDC3000TDC3000DatabaseDatabase


ControllerControllerGUIGUISimulatorSimulator


ControllerControllerGUIGUI

GatewayGateway


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Scenario 3: DependabilityScenario 3: Dependability

Not sure if possible address it (not enough time)


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Main requirementsMain requirements

Components:• Physical process• Field devices: sensor, controller, actuator• Displays (GUI)• Legacy systems: Honeywell TDC3000• Simulator

Capabilities:• Management of asynchronous events• Reconfigurability• Hot swapping• Operational status self-detection of every node• Concurrent access support• Synchronization of the signals


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Capabilities (cont)Capabilities (cont)

Remote access from any node to any node in the system.

Redundancy of critical elements (networks and some controllers).

Alarm status availability of any node in the display Error detection and recovery Scalability Possibility to connect to other systems (OPC,...) Smooth node reinitialization or after the node is

reinstated


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HRTCUPM LTH TUW SCI

IST 37652


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HMI

DCS SimulatorIED

ReplicatedRT-DB

Scenario 3Scenario 3


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Scenarios

FIGURA DEL PRIMER ESCENARIO:

DESARROLLO DE LA PCT.

Scenario I: Development of the PCT

Experiments on S-I:• •


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FIGURA DEL SEGUNDO ESCENARIO:

FUNCIONAMIENTO DE LA PCT.

Scenario II: Normal operation of the PCT

Experiments on S-II:• •


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FIGURA DEL TERCER ESCENARIO:

ERRORES EN LA PCT.

Scenario III: Abnormal functioning of the PCT

Experiments on S-III:• •


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IIOP ORB

Gateway

Workstation

DCS Simulator

Logger

Supervision

IED

RT-DB

ORB


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resourcesresources


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Documents

HRTC Hard Real-time CORBA IST 37652 WP4 / Viena September 11-13, 2002 1 Process Control Testbed Manuel Rodríguez Santos Galán Universidad Politécnica de