OPC connectivity in the feedback of a municipal-wide heating closed control system

1. OPC connectivity in the feedback of a municipal-wide heating closed control system Mariusz Postół Przemyslaw Malek www.cas.eu

2. CONTROL PROCESS • Łódź citizens #: 1M • Heating plants: 3 • Total thermal output: 2560MW • Heat distribution network:~800km ~500miles • Number of nodes: ~7 000 • Production in cogeneration: • Hot water • Electric power • Steam

3. PRODUCTION OBJECTIVES f=f( ) f=y( )

4. CONTROL OBJECTIVE H1 H2 H3 Heat stream = f(weather) HEAT STREAM

5. SUPPLY AREA MANAGEMENT

6. FIRST STAGE K-1266 K-209 K-231 K-199 K-736 K-22 K-751 K-762 K-175 K-1014/1 K-164 K-1023 K-104/30 K-110 K-104/A K-101 SMULSKO HDCR OFFICE K-637 K-617 K-510

7. COMMON AREAS K-1266 K-209 K-231 K-199 K-736 K-22 K-751 K-762 K-175 K-1014/1 K-164 K-1023 K-104/30 K-110 K-104/A K-101 SMULSKO K-637 K-617 K-510

8. Łódź Punkt krytyczny Punkt krytyczny Punkt krytyczny Punkt krytyczny Punkt krytyczny Pz = ? R(x) = ? Pz = ? R(p) = ? Pz = ? Radogoszcz Teofilów Communication Śródmieście Smulsko Janów Dąbrowa Chojny

9. AUTOMATIC LOAD CONTROL LOAD LOAD SEPARATION P P P P G K - 101 K - 164 P P F 3 F 4 REFILL REFILL SUW SUW AREA 1 AREA 2

10. AUTOMATIC LOAD CONTROL PLC PLC HDCS REFILL REFILL OPC HDCS SUW SUW LOAD LOAD P K - 101 K - 164 OPC Connectivity

11. Communication paths

12. Communication paths Division Heating Chamber Regulation Heating Chamber Power Plant #1 Power Plant #2 Redundancy Control ?

13. COMMUNICATION SERVER interface interface interface interface interface interface interface interface PIPE PIPE PIPE PIPE PIPE PIPE PIPE PIPE SEGMENT SEGMENT SEGMENT SEGMENT PROTOCOL PROTOCOL PROTOCOL PROTOCOL PROTOCOL SEGMENT MEDIUM MEDIUM MEDIUM MEDIUM MEDIUM CommServer CHANNELS SCADA Stations OPC Connectivity

14. interface interface interface interface interface interface interface interface Division Heating Chamber Regulation Heating Chamber PIPE PIPE PIPE PIPE PIPE PIPE PIPE PIPE SEGMENT SEGMENT SEGMENT SEGMENT SBUS SBUS/UDP SBUS/UDP GPRS RADIO Ethernet CommServer CHANNELS SCADA Stations OPC Connectivity Example – Lodz common heating network Power Plant #1 Power Plant #2

15. Commserver - Redundancy Active Wait for failure Active SERVICE Standard solution – better case Primary Station LAN Backup Station

16. Commserver - Redundancy Active Active Standby CommServer Standby Standby Active SERVICE Fail Commserver solution

17. DEVICE COMMUNICATION MESS WS WS ES OPC SERVER PROCESS APPLICATION

18. DEVICE COMMUNICATION MANAGEMENT F( ) ? WS WS ES SCANNER CACHE OPC - Interface SERVER

19. PROCESS REQUIREMENTS DIRECTION K101 DIRECTION K617

20. DIAGRAM OF DIRECTION STATES ACCEPTED LATENCY HOURS ACCEPTED LATENCY HOURS MONTHS MINUTES MONTHS CLOSING DONE CLOSE CLOSED OPENED ACCEPTED LATENCY SECONDS OPEN OPENING DONE

21. ADAPTIVE APPROACH CLOSING OPENING CLOSED OPENED STATE DRIVEN SCANNING POLICY SCANNING ON DEMAND SLOW SLOW FAST SLOW:POLICY FAST:POLICY SLOW:POLICY

22. Commserver – SCANNING ON DEMAND CommServer Normal state – slow scanning

23. Commserver – SCANNING ON DEMAND CommServer Alarm state – fast scanning

24. Commserver – multi-channel Typical solution Object #1 Object #2 Object #3 Object #n 1000 objects ? GPRS round trip> 2 sec. => Cycle time > 0.5h

25. Commserver - Multichannel CommServer Multichannel solution Object #1 Object #2 Object #3 Object #4 1000 objects ? Object #5 Object #6 Object #7 Object #8 250 channels Object #n 8 sec. Object #n+1 Object #n+2 Object #n+3

26. OPC TRANSPORTER OPCT SQL OPCS OPCS XML OPC CONNECTIVITY SQL CONNECTIVITY XML CONNECTIVITY TAGS TAGS QUEUES TAGS - a - b - c - d - Q1 - Q2 - Q3 - Q4 - aa - bb - cc - dd - P1 - P2 - P3 - P4 HORIZONTAL VERTICAL a = aa + 10 bb Average(a, b, c, d) P1 = aa+a+... PUSH(Q1, d+c)

27. Thank you for your time

28. SYSTEMS INTEGRATION - GIS SPM SOC Kxxx Kxxx Kxxx Kxxx WIZ OPCS OPCS OPCS SOC GIS SOC SOC TCH SOC KOM KOM TCH View View KDs SBs SBk UNTOUCHABLE SCk SCs GIS ORACLE VLAN NAT SYM UNTOUCHABLE SERWER Corporate field network Corporate network EC EC EC

29. PASSIVE OPC SERVER OPC INTERFACES CACHE MASTER WS WS SNIFFER PASSIVE MONITOR RS485 ETHERNET

30. Integration Data Sources > 90 % BUDGET Object Services Heat meters 5000 pcs. (70000 variables) Access Points 1000 pcs. Business Services ERP, CRM, DB, Accounting Data Services Communication Servers OPC, SQL, XML/HTML Thermal-PowerPlants 60 pcs. (1000 variables) Presentation Services Heating chambers, Pomp stations 25 pcs. (3000 variables) SCADA, Reports Corporate LAN

31. Hydrostatic Thermostatic Hydrostatic P limit Hydrodynamic

32. SYSTEM INTEGRATION SPM SOC TCH SOC TCH SOC SOC View View KDs SBs GIS SERVR Corporate field network Corporate network EC EC EC SCs

33. SYSTEMS INTEGRATION SOC Kxxx Kxxx Kxxx Kxxx TCH SOC KOM TCH SOC SOC KOM View View SBk GIS SQL VLAN NAT SYM SERVER Corporate field network Corporate network EC EC EC WALL SCREEN OPC SQL

34. GIS SMALLWORD OPC COMMSERVER SQL ORACLE OPC TRANSPORTER OPC TRANSPORTER STATISTIC PROCESSOR TRANSPORT ENGINE XML OPC SQL CONFIGURATION

35. AUTOMATIC LOAD CONTROL ODBIORY ODBIORY PODZIAŁ EC - 3 EC - 2 P P P P G F 1 = const F 2 K - 101 K - 164 P P P P G F 3 F 4 UZUPEŁNIANIE UZUPEŁNIANIE SUW SUW

36. Crash OPCS OPCS WS WS

37. Solution OPCS OPCS WS WS Cooperation REPLACE Competition

38. Solution CONTROL OPCS OPCS ISLAND OF AUTOMATION ISLAND OF AUTOMATION ISLAND OF AUTOMATION WS WS CONTROL MUTUALY ECLUSIVE

39. THE MESSAGE IS: OPC CFIS SOC APP HARDWARE SOFTWARE INTEGRATION SKILLS TECHNOLOGY KNOWLEDGE DEVELOPMENT

40. Commserver - Redundancy Active Wait for failure Standard solution – worse case Primary Station NO Connection !!! LAN Backup Station SERVICE