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Process Analyzer Connectivity Initiative (ConnI) A Status Report. Ron O’Reilly Dow Chemical Canada Inc. Fort Saskatchewan, AB Canada. Peter van Vuuren ExxonMobil Chemical Baytown, Texas USA. Topics. Functional Domain and Connectivity Model for Process Analyzer System - Overview
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Process Analyzer Connectivity Initiative (ConnI) A Status Report Ron O’ReillyDow Chemical Canada Inc.Fort Saskatchewan, ABCanada Peter van VuurenExxonMobil Chemical Baytown, TexasUSA
Topics • Functional Domain and Connectivity Model for Process Analyzer System - Overview • Measurement Domain • DCS Domain • Model - O&M Domain • Model - Enterprise Model • A Summary
ConnI recognizes that a process analyzer isnot a stand-alone entitybut has only added value if throughconnectivityit is anintegralcomponent of several relatedsystem domains: Connectivity Role • Measurement domain: integrated with other analyzers • DCS domain: DCS is itsprimary customer • Analyzer Operations/Maintenance domain: Support system for reliable operation and effective user interfaces • Enterprise domain: Must allow remote access and support
Hierarchical/Domain* Model for Process Analyzer System - Overview Level 4 Enterprise LAN EnterpriseDomain Safety Level 3 LAN O&MDomain DCSDomain Control/Optimization c-LAN AnLAN Environmental Level 2 LAN = Field LAN Primary Data Path > Requires Maximum Integrity/Reliability Secondary Data Path > Requires HighIntegrity/Reliability SAM Level 1 SensorBus (CAN) Measurement Data(Validated)Status/Change Info DCS Data +:Raw Data/Calibration/SQCDiagnostics/Alarms eSAM Limited Control Functions MeasurementDomain Configuration DataAll Control Functions * Functional Domains NOT Computer Domains L4 L3 L2 L1 L0
Hierarchical/Domain Model for Process Analyzer System - Measurement Domain Ent DCS O&M Level 1 Bus (CAN) Measurement SAM SAM Level 1 SensorBus (CAN) eSAM eSAM MeasurementDomain • Modular Smart Sampling System(NeSSI) • Sample, Condition and Validate Process Sample • Multiple Sensors (may be Physical and Analytical) • Level 1 Sensor Bus (CAN -based SDS or DeviceNet) Small Footprint Configuration via Flash Memory Existing and Mature Technology - Inexpensive Components CAN-based communications already in use by Major Suppliers • Future Goal is Wireless Communications (NeSSI III)
Hierarchical/Domain Model for Process Analyzer System - Measurement Domain Ent DCS O&M Level 1 Bus (CAN) Measurement SAM SAM Level 1 SensorBus (CAN) eSAM eSAM MeasurementDomain • Sensor/Actuator Manager (SAM) • SAM is a Sampling System ControllerManages all Sampling System Functions and DiagnosticsCollects and Validate Sensor Information (Analytical Sensor information Converted by Analyzer Controller) • Examples of Functions:Responsible for Stream Sequencing (Valve Actuation)Control Sampling System Heating/CoolingMeasures all physical Properties of Sample (e.g.. T,P,F)Collects Maintenance & Diagnostic Information(SAM is key to successful Preventative Maintenance System) • SAM can be a Stand-alone Level 2 Controller Device communicating via the Level 2 LAN with it’s Host Controller • SAM Functionality can be embedded in an Analyzer Controller (e.g. GC Controller) • Standardized Communications between Sensors and SAM of critical importance if NeSSI Sampling systems are to be successful • Connectivity Issues:CAN-based specification (2002/2003)SAM/Host Analyzer Controller Functional Specification • SAM is likely a WIN CE device which can also support OPC Communications between SAM and Host Controller
Hierarchical/Domain Model for Process Analyzer System - Measurement Domain Ent DCS O&M Level 1 Bus (CAN) Measurement SAM SAM Level 1 SensorBus (CAN) eSAM eSAM MeasurementDomain • Analyzer Controller • Responsible for the Measurement and Overall Validation of Result(s)Support and Validation of Sampling System via SAM (Embedded or Remote) • Update DCS System via OPC Gateway Server or other Datalink Types (OPC Server may be Embedded) • Update Short Term Data Server • Support User Interface at Workstations (Multiple User Interfaces from Different Analyzer Controllers must co-exist) • Scalable Platforms (WinCE to Windows XP/2000) • Connectivity Issues:Protocol for Updating OPC DCS Gateway ServerUser Interface Communications ProtocolsDatabase Server Protocols
Raman FTNIR GC GC Proposed Connectivity Model for Measurement Domain Diversity of Analyzer Devices that makes up the Measurement Domain Anlzr Level 2 FLAN Spectral Fiber (Private IP Addresses) GP Area - Control/Analyzer/RIB Room Fiber -optic link Fiber -optic link Field Anlzr Level 2 FLAN AnalyzerControl SAM SAM SAM GC GC GC Anlzr Level 1Sensor Bus (CAN) Sampling Systems EmbeddedSAM
Define the Physical Layers for Level 1/2/3* Level 1 : CAN bus* Level 2/3: Ethernet TCP/IP (Industrial) Identify Compatible High-level Communication Protocols (peaceful co-existence on same workstations, servers etc.)* OPC* HTTP* Fieldbus etc. Define Functional requirements for Data Server, Workstations and Long Term Historian Define Requirements for Analyzer-DCS Data Link Interface* Draft Specification posted on CPAC ConnI website ConnI Goals
Hierarchical/Domain Model for Process Analyzer System - DCS Domain Ent SAM FTNIR eSAM DCS O&M Long Term Historian Level 1 Bus (CAN) Measurement DCSDomain Analyzer GatewayOPC Server(AGS) OPC ClientBridge(CB) EmbeddedDCS OPCClient(EDC) EmbeddedAnalyzer OPC Server(AES) DCS OPC Server Not showing Operator Consoles
Hierarchical/Domain Model for Process Analyzer System - DCS Domain Ent SAM FTNIR eSAM • How do we “stitch these together? * Ethernet & TCP/IP • What information do we exchange? * Draft OPC DCS/Analyzer Datalink * Soliciting Comments * Soliciting Endorsements * Testing Underway or Planned with Several Process Control and Process Analyzer Vendors DCS O&M Level 1 Bus (CAN) Measurement DCSDomain EDC CB AGS AES Not showing Operator Consoles
Hierarchical/Domain Model for Process Analyzer System - DCS Domain Ent SAM FTNIR eSAM • DCS Analyzer OPC Client • DCS Analyzer OPC Client:* Setup and Configuration based on Analyzer OPC Server Database* Should be based on OPC Standard 2.0* DCS Client linked to DCS Specific OPC Server* Communication with OPC Analyzer Server via Ethernet TCP/IP • Configuration of OPC Client should be based on using standard OPC 2.0 Configuration Software e.g., “subscribing” to the individual analyzer OPC data elements such as “Analyzer Status” • The DCS Client can be implemented as:* Embedded DCS Client (integrated with the DCS OPC Server and supported by the DCS Supplier)* Client Bridge i.e., “Double Headed Client” - Presents itself as a Client to the Analyzer OPC Server - Presents itself as a Client to the DCS OPC Analyzer Server - Typically provided/supported by a Third Party DCS O&M Level 1 Bus (CAN) Measurement DCSDomain EDC CB AGS AES Not showing Operator Consoles
Hierarchical/Domain Model for Process Analyzer System - DCS Domain Ent SAM FTNIR eSAM • Analyzer OPC Server • Implemented either as a “Gateway” (AGS) or Embedded Server (AES) • TCP/IP - OPC is currently the protocol of choice for communications between computers in the DCS World - in process of adapting it as the basis for an Analyzer/DCS Datalink • Progress:Preliminary Specification Developed:* Client/Server Topologies* Addressing Scheme* OPC Server Content Summarized Later • Status/Plans:* Draft specification posted on CPAC ConnI website 2Q02* Complete Specification in 1Q03 as part of ConnI effort* Testing to continue 3Q02 - 2Q03 (Several Control System/Analyzer Vendors)* Solicit endorsements from end-users, analyzers suppliers and DCS vendors DCS O&M Level 1 Bus (CAN) Measurement DCSDomain EDC CB AGS AES Not showing Operator Consoles
Hierarchical/Domain Model for Process Analyzer System - DCS Domain Ent SAM FTNIR eSAM • DCS/Analyzer OPC Datalink Specification • Draft Specification posted for comments on CPAC ConnI website • Complete Final Specification in 1Q03 as part of ConnI effort • Continue testing with several Process Control/Process Analyzer Vendors • Solicit endorsements from other analyzer and DCS vendors • Specification Addresses Three Key Functions: • * Client/Server Topologies* Addressing Scheme* OPC Server Content/Failure Recovery DCS O&M Level 1 Bus (CAN) Measurement DCSDomain EDC CB AGS AES Not showing Operator Consoles
OPC Datalink Specification -Analyzer Operations as Event Driven Functions Initialization Data Status Change Fault Recovery Specification allows for Bidirectional control:DCS Console Operator can Request Status Change e.g.* Start/Stop an Analyzer* Enable/Bypass a Stream* Change the Sequence of Streams to be Analyzed
1 1 1 1 1 2 n Summary of Possible Analyzer Controller and Stream Configurations Detector/Probe Streams = STRM Components = COMP Configuration Types Controller CAP Examples TYPE 1a Single ControllerSingle CAP Single Detector/Probe/Stream Single Component pHConductivity OxygenAutotitrator TYPE 1b Single Controller Single CAP Single Detector/Probe/Stream Multiple Components PhotometerSimple GC TYPE 2a Single ControllerSingle CAP Multiple Detectors/Probes/Streams Single Component Panametrics GC RegularGC Master/Slave FTIRRAMANMass Spec TYPE 2b Single Controller Single CAPMultiple Detectors/Probes/Streams Multiple Components TYPE 3 Single Controller Multiple CAP Multiple Detectors/Probes/Streams Single/Multiple Components GC Master/Master FTIRRAMAN
Hierarchical/Domain Model for Process Analyzer System - O&M Domain Ent SAM eSAM DCS O&M Level 1 Bus (CAN) Measurement • Analyzer Workstation • Primary Maintenance/Operations Window into Process Analyzer System • Key Functions:* Upload and Download of Analyzer Configuration/Methods* Access of Real-time Diagnostic/Analyzer Data @ Analyzer* Access of Diagnostic/Analyzer Data @ Analyzer Server* Access and Configuration of SQC Data/Run-time Rules @ Server • Specification Work to begin in 2003 O&MDomain AnLAN
Hierarchical/Domain Model for Process Analyzer System - O&M Domain Ent SAM eSAM DCS O&M • Analyzer Server • Short Term ( ~ 1 month(?)) Data Archive* Raw Data for all assigned Analyzers* Operational Data Storage (Methods/Configurations etc.)* Primary Database for Workstation Access * Serves as Front-end to Long-term Data Archive • Connectivity/Specification Issues:* Database Type(s)- ODBC vs. Others* Co-existence of Analyzer Data from Different Vendors* Communications Protocol for Data Exchange between Analyzer and Server • Specification Work to begin in 2003 Level 1 Bus (CAN) Measurement O&MDomain AnLAN
Hierarchical/Domain Model for Process Analyzer System - O&M Domain Ent SAM eSAM DCS O&M • Analyzer/DCS Long Term Data Archive • May be located in O&M Domain or DCS Domain (see DCS Domain functions) • If located and supported in the O&M Domain, typically would only store Analyzer Data • May require translation software to Update Long Term Archive from Short Term Analyzer Archive (See Analyzer O&M Domain) Level 1 Bus (CAN) Measurement O&MDomain AnLAN
Work-station Work-station FTNIR Raman Proposed Connectivity Model - DCS Datalink Client/Server Topologies One of many ways a system can be stitched together Plant LAN IntraNet OPC ClientBridge(CB) LEVEL 3/4Router Analyzer GatewayOPC Server(AGS) PDC Historian EmbeddedDCS OPCClient(EDC) DCS OPC Server Server/ Workstations DCS Level 2 LAN (TDC=LCN) E.g. Cisco2950 VLANSwitch/Router EmbeddedAnalyzer OPC Server(AES) Anlzr Level 2 FLAN (Private IP Addresses)
ConnI Status Report: Summary • Draft OPC DCS/Analyzer Datalink specification published for comments* Testing Planned or Underway with Several Process Control/Process Analyzer Vendors • Solicitation of Endorsements/comments/changes from analyzer suppliers/DCS vendors and end-users underway • Overall Architecture well in place - Generic Functional Specification aimed for 2003 • Functional specification for NeSSI Sensor bus and SAM (part of NeSSI Gen II specification) to be published soon (NeSSI Website) • Prototype Proof of Concept Apparatus (POCA) systems being developed by Honeywell* Based on IS CANbus* Will allow for testing of SAM functionality