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Process Control Testbed

Process Control Testbed. Manuel Rodríguez Santos Galán Universidad Politécnica de Madrid. Outline. Process Industry Control Manufacturers Process Control Testbed . Process Industry. Refining Power Chemical Pharmaceutical Cement Food Plastics Water & Waste. Cement process.

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Process Control Testbed

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  1. Process Control Testbed Manuel Rodríguez Santos Galán Universidad Politécnica de Madrid WP4 / Viena September 11-13, 2002

  2. Outline • Process Industry • Control Manufacturers • Process Control Testbed WP4 / Viena September 11-13, 2002

  3. Process Industry • Refining • Power • Chemical • Pharmaceutical • Cement • Food • Plastics • Water & Waste WP4 / Viena September 11-13, 2002

  4. Cement process Ethylene process WP4 / Viena September 11-13, 2002

  5. Process control levels WP4 / Viena September 11-13, 2002

  6. Distributed Control SystemTraditional approach . WP4 / Viena September 11-13, 2002

  7. Control Manufacturers WP4 / Viena September 11-13, 2002

  8. Emerson (Fisher-Rosemount) 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 WP4 / Viena September 11-13, 2002

  9. DeltaV Incorporates OPC for integration with business applications The Control Network is an ethernet network. Several fieldbuses integration Fieldbus,Profibus,HART... WP4 / Viena September 11-13, 2002

  10. WP4 / Viena September 11-13, 2002

  11. Honeywell 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. WP4 / Viena September 11-13, 2002

  12. WP4 / Viena September 11-13, 2002

  13. WP4 / Viena September 11-13, 2002

  14. Invensys (Foxboro) I/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.  WP4 / Viena September 11-13, 2002

  15. 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. WP4 / Viena September 11-13, 2002

  16. 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 signals and 180000 signals from serial inputs WP4 / Viena September 11-13, 2002

  17. WP4 / Viena September 11-13, 2002

  18. Yokogawa STARDOM WP4 / Viena September 11-13, 2002

  19. WP4 / Viena September 11-13, 2002

  20. Trends 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 WP4 / Viena September 11-13, 2002

  21. Network 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” WP4 / Viena September 11-13, 2002

  22. Process Control Testbed • The HRTC Contract • composability in heterogeneous process control applications WP4 / Viena September 11-13, 2002

  23. PCT 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,...) WP4 / Viena September 11-13, 2002

  24. PCT Scenarios • Heterogeneity • Interoperation of heterogeneous subsystems • Scalability • Addressing large process control • Dependability • Reliability • Availability • Maintainability WP4 / Viena September 11-13, 2002

  25. Scenario 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 WP4 / Viena September 11-13, 2002

  26. Simulator GUI Controller Sensor Actuator TDC3000 Database PROCESS Scenario 1 WP4 / Viena September 11-13, 2002

  27. Scenario 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 WP4 / Viena September 11-13, 2002

  28. Scenario 2.1 Simulator HMI ORB Plant DCS RT-DB WP4 / Viena September 11-13, 2002

  29. Simulator GUI Controller Sensor Actuator TDC3000 Database PROCESS Gateway GUI Controller Sensor Actuator Scenario 2.2 WP4 / Viena September 11-13, 2002

  30. Scenario 3: Dependability • Not sure if possible address it (not enough time) WP4 / Viena September 11-13, 2002

  31. Main 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 WP4 / Viena September 11-13, 2002

  32. 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 WP4 / Viena September 11-13, 2002

  33. UPM LTH TUW SCI HRTC IST 37652 WP4 / Viena September 11-13, 2002

  34. Scenario 3 ReplicatedRT-DB HMI IED DCS Simulator WP4 / Viena September 11-13, 2002

  35. Scenarios Scenario I: Development of the PCT FIGURA DEL PRIMER ESCENARIO: DESARROLLO DE LA PCT. • Experiments on S-I: WP4 / Viena September 11-13, 2002

  36. WP4 / Viena September 11-13, 2002

  37. Scenario II: Normal operation of the PCT FIGURA DEL SEGUNDO ESCENARIO: FUNCIONAMIENTO DE LA PCT. • Experiments on S-II: WP4 / Viena September 11-13, 2002

  38. Scenario III: Abnormal functioning of the PCT FIGURA DEL TERCER ESCENARIO: ERRORES EN LA PCT. • Experiments on S-III: WP4 / Viena September 11-13, 2002

  39. IIOP ORB Supervision Workstation RT-DB Logger Gateway ORB IED DCS Simulator WP4 / Viena September 11-13, 2002

  40. resources WP4 / Viena September 11-13, 2002

  41. WP4 / Viena September 11-13, 2002

  42. WP4 / Viena September 11-13, 2002

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