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

2. HRTC IST 37652 Hard Real-time CORBA WP4 / Viena September 11-13, 20022 Outline  Process Industry  Control Manufacturers  Process Control Testbed

3. HRTC IST 37652 Hard Real-time CORBA WP4 / Viena September 11-13, 20023 Process Industry  Refining  Power  Chemical  Pharmaceutical  Cement  Food  Plastics  Water & Waste

4. HRTC IST 37652 Hard Real-time CORBA WP4 / Viena September 11-13, 20024 Cement process Ethylene process

5. HRTC IST 37652 Hard Real-time CORBA WP4 / Viena September 11-13, 20025 Process control levels

6. HRTC IST 37652 Hard Real-time CORBA WP4 / Viena September 11-13, 20026. Distributed Control System Distributed Control System Traditional approach

7. HRTC IST 37652 Hard Real-time CORBA WP4 / Viena September 11-13, 20027 Control Manufacturers

8. HRTC IST 37652 Hard Real-time CORBA WP4 / Viena September 11-13, 20028 ) 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

9. HRTC IST 37652 Hard Real-time CORBA WP4 / Viena September 11-13, 20029 DeltaV Several fieldbuses integration Fieldbus,Profibus,HART... The Control Network is an ethernet network. Incorporates OPC for integration with business applications

10. HRTC IST 37652 Hard Real-time CORBA WP4 / Viena September 11-13, 200210

11. HRTC IST 37652 Hard Real-time CORBA WP4 / Viena September 11-13, 200211 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.

12. HRTC IST 37652 Hard Real-time CORBA WP4 / Viena September 11-13, 200212

13. HRTC IST 37652 Hard Real-time CORBA WP4 / Viena September 11-13, 200213

14. HRTC IST 37652 Hard Real-time CORBA WP4 / Viena September 11-13, 200214 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. HART FOUNDATION fieldbusProfibus FoxCom

15. HRTC IST 37652 Hard Real-time CORBA WP4 / Viena September 11-13, 200215  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.

16. HRTC IST 37652 Hard Real-time CORBA WP4 / Viena September 11-13, 200216 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

17. HRTC IST 37652 Hard Real-time CORBA WP4 / Viena September 11-13, 200217

18. HRTC IST 37652 Hard Real-time CORBA WP4 / Viena September 11-13, 200218 Yokogawa STARDOM

19. HRTC IST 37652 Hard Real-time CORBA WP4 / Viena September 11-13, 200219

20. HRTC IST 37652 Hard Real-time CORBA WP4 / Viena September 11-13, 200220 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

21. HRTC IST 37652 Hard Real-time CORBA WP4 / Viena September 11-13, 200221 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”

22. HRTC IST 37652 Hard Real-time CORBA WP4 / Viena September 11-13, 200222 Process Control Testbed  The HRTC Contract composability in heterogeneous process control applications

23. HRTC IST 37652 Hard Real-time CORBA WP4 / Viena September 11-13, 200223 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,...)

24. HRTC IST 37652 Hard Real-time CORBA WP4 / Viena September 11-13, 200224 PCT Scenarios  Heterogeneity Interoperation of heterogeneous subsystems  Scalability Addressing large process control  Dependability Reliability Availability Maintainability

25. HRTC IST 37652 Hard Real-time CORBA WP4 / Viena September 11-13, 200225 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

26. HRTC IST 37652 Hard Real-time CORBA WP4 / Viena September 11-13, 200226 Scenario 1 PROCESS TDC3000 Database Sensor Actuator Controller GUI Simulator

27. HRTC IST 37652 Hard Real-time CORBA WP4 / Viena September 11-13, 200227 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

28. HRTC IST 37652 Hard Real-time CORBA WP4 / Viena September 11-13, 200228 Scenario 2.1 DCS Simulator HMI RT-DB ORB Plant

29. HRTC IST 37652 Hard Real-time CORBA WP4 / Viena September 11-13, 200229 Scenario 2.2 PROCESS TDC3000 Database Sensor Actuator Controller GUI Simulator Sensor Actuator Controller GUI Gateway

30. HRTC IST 37652 Hard Real-time CORBA WP4 / Viena September 11-13, 200230 Scenario 3: Dependability  Not sure if possible address it (not enough time)

31. HRTC IST 37652 Hard Real-time CORBA WP4 / Viena September 11-13, 200231 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

32. HRTC IST 37652 Hard Real-time CORBA WP4 / Viena September 11-13, 200232 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

33. HRTC IST 37652 Hard Real-time CORBA WP4 / Viena September 11-13, 200233 HRTC UPM LTH TUW SCI IST 37652

34. HRTC IST 37652 Hard Real-time CORBA WP4 / Viena September 11-13, 200234 HMI DCSSimulator IED Replicated RT-DB Scenario 3

35. HRTC IST 37652 Hard Real-time CORBA WP4 / Viena September 11-13, 200235 Scenarios FIGURA DEL PRIMER ESCENARIO: DESARROLLO DE LA PCT. Scenario I: Development of the PCT Experiments on S-I:

36. HRTC IST 37652 Hard Real-time CORBA WP4 / Viena September 11-13, 200236

37. HRTC IST 37652 Hard Real-time CORBA WP4 / Viena September 11-13, 200237 FIGURA DEL SEGUNDO ESCENARIO: FUNCIONAMIENTO DE LA PCT. Scenario II: Normal operation of the PCT Experiments on S-II:

38. HRTC IST 37652 Hard Real-time CORBA WP4 / Viena September 11-13, 200238 FIGURA DEL TERCER ESCENARIO: ERRORES EN LA PCT. Scenario III: Abnormal functioning of the PCT Experiments on S-III:

39. HRTC IST 37652 Hard Real-time CORBA WP4 / Viena September 11-13, 200239 IIOP ORB Gateway Workstation DCSSimulator Logger Supervision IED RT-DB ORB

40. HRTC IST 37652 Hard Real-time CORBA WP4 / Viena September 11-13, 200240 resources

41. HRTC IST 37652 Hard Real-time CORBA WP4 / Viena September 11-13, 200241

42. HRTC IST 37652 Hard Real-time CORBA WP4 / Viena September 11-13, 200242