opc connectivity in the feedback of a municipal-wide heating closed control system
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1
OPC connectivity in the feedback of a municipal-wide heating closed control
system
Mariusz PostółPrzemyslaw 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
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PRODUCTION OBJECTIVES
=f( )
=y( )
4
CONTROL OBJECTIVE
HEAT STREAM
H1 H2
H3
Heat stream = f(weather)
5
SUPPLY AREA MANAGEMENT
6
K-231
K-1266
K-209
K-101
K-751
K-762
K-736
SMULSKO
K-510K-617
K-110 K-104/30
K-164
K-175
K-104/A
K-199
K-1014/1
K-22
K-1023
K-637
FIRST STAGE
HDCR
OFFICE
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K-231
K-1266
K-209
K-101
K-751
K-762
K-736
SMULSKO
K-510K-617
K-110 K-104/30
K-164
K-175
K-104/A
K-199
K-1014/1
K-22
K-1023
K-637
COMMON AREAS
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Punkt krytyczny
Punkt krytyczny
Punkt krytyczny
Punkt krytycznyPunkt krytyczny
Łódź
Śródmieście
Janów
Chojny
Smulsko
Teofilów
Radogoszcz
Dąbrowa
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AUTOMATIC LOAD CONTROL
K-101
F3
REFILL
F4
SUWSUW
K-164
P
G
LOAD
SE
PA
RA
TIO
N
P
P P
P P
LOAD
REFILL
AREA 1AREA 1 AREA 2AREA 2
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HDCSHDCS
HDCSHDCS
AUTOMATIC LOAD CONTROL
K-101
LOAD
REFILLSUW
K-164
P
LOAD
SUW
REFILL
OPC Connectivity
PLCPLC
PLCPLC
OPCOPC
11
Communication paths
EC-3 EC-2
K-101
ODBIORY
F1=constF2
F3
UZUPEŁNIANIE
F4
UZUPEŁNIANIE
SUWSUW
K-164
P
P P
P P
PG
G
P
ODBIORY
P
SAIAPCD2
SAIAPCD4
SAIAPCD4
Wizcon
SIEĆ TECHNOLOGICZNA
SAIAPCD2
Budynek Łączności EC2
FO
Wizcon1
Wizcon2
Stacja bazowa
RS 232
RS 232
`
RS 485
ZSC
`
KościuszkiMDS
DS
RS 232 over TCP/IP
Interfejs dla innych
urządzeń
K954
FzPzPp
SAIAPCD1
Stacja Demi
Fu1Fu2 Wizcon
SAIAPCD1
`
SAIAPCD1
12
Communication paths
Power Plant #1
Power Plant #2
Regulation Heating Chamber
Division Heating Chamber
Redundancy
13
COMMUNICATION SERVER
CHANNELS
OPC Connectivity
MEDIUM
PROTOCOL
MEDIUM
PROTOCOL
MEDIUM
PROTOCOL
MEDIUM
PROTOCOL
SEGMENTSEGMENT
MEDIUM
PROTOCOLSEGMENT
SEGMENTSEGMENT
PIPE
interface
interface
PIPEPIPE
interface
interface
PIPE PIPE
interface
interface
PIPE PIPEin
terface
interface
PIPE
SCADA Stations
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Example – Lodz common heating network
Power Plant #1
Power Plant #2
Regulation Heating Chamber
Division Heating Chamber
OPC Connectivity
SCADA Stations
CHANNELS
Ethernet
SBUS/UDP
SEGMENT
RADIO
SBUS
SEGMENTSEGMENT
PIPE
interface
interface
PIPE PIPE
interface
interface
PIPEPIPE
interface
interface
PIPEPIPE
interface
interface
PIPE
GPRS
SBUS/UDP
SEGMENT
15
Commserver - Redundancy
Primary Station
Standard solution – better case
Backup Station
LAN
Wait for failure
Active
SERVICE
Active
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Commserver - Redundancy
Commserver solution
SERVICE
Standby
ActiveStandby
Active
Standby
Active
Fail
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WS
WS
ES
DEVICE COMMUNICATION MESS
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DEVICE COMMUNICATION MANAGEMENT
SERVER
SC
AN
NE
R
CA
CH
E
OP
C -
Inte
rfac
e
WS
WS
ES
F( ) ?
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PROCESS REQUIREMENTS
DIR
EC
TIO
N K
101
DIRECTION K617
20MINUTESMINUTES MONTHSMONTHSMONTHSMONTHS
DIAGRAM OF DIRECTION STATES
CLOSEDCLOSED
CLOSINGCLOSING
OPENEDOPENED
OPENINGOPENING
DONE
CLOSE
DONE
OPEN
ACCEPTEDLATENCY
HOURS
ACCEPTEDLATENCY
HOURS
ACCEPTEDLATENCY
HOURS
ACCEPTEDLATENCY
HOURS
ACCEPTEDLATENCYSECONDS
ACCEPTEDLATENCYSECONDS
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ADAPTIVE APPROACH
CLOSEDCLOSED OPENEDOPENED
CLOSINGCLOSING
OPENINGOPENING
SLOWSLOW SLOWSLOWFASTFAST
STATE DRIVEN SCANNING POLICY
SLOW:POLICY SLOW:POLICYFAST:POLICY
SCANNING ON DEMANDSCANNING ON DEMAND
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Commserver – SCANNING ON DEMAND
Normal state – slow scanning
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Commserver – SCANNING ON DEMAND
Alarm state – fast scanning
24
Commserver – multi-channel
GPRS round trip > 2 sec. => Cycle time > 0.5h
Typical solution Object #1
Object #2
Object #3
Object #n
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Commserver - Multichannel
Object #1
Object #2
Object #3
Object #4
250 channels
Multichannel solution
Object #5
Object #6
Object #7
Object #8
Object #n
Object #n+1
Object #n+2Object #n+3
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OP
CT
SQ
L
P1 = aa+a+...
PUSH(Q1, d+c)
OPC TRANSPORTER
SQL CONNECTIVITY
XML CONNECTIVITY
OPC CONNECTIVITY
a = aa + 10 bb
Average(a, b, c, d)
HORIZONTAL
VE
RT
ICA
L
XM
L
- P1- P2- P3- P4
TAGS
- Q1- Q2- Q3- Q4
QUEUES
OP
CS
- aa- bb- cc- dd
TAGS
OP
CS
- a- b- c- d
TAGS
27
Thank you for your time
28
NAT
KxxxKxxx
KxxxKxxx
SCk
VLANSYM
SOC
SOC
SB
s
SCs
SOCSOC K
Ds
SPM
TCH
TCH
Corporate field network
EC EC EC
KOM
KOM
ORACLE
View
SE
RW
ER
Corporate network
GIS
View
SB
k
SYSTEMS INTEGRATION - GIS
WIZ
OP
CS
OP
CS
OP
CSS
OC
GISUNTOUCHABLE
UNTOUCHABLE
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MASTER
RS485 ETHERNET
WS
WS
PASSIVE OPC SERVER
PASSIVE
MONITOR
CACHE
OPC
INTERFACES
30
Integration
Access Points 1000 pcs. Communication
Servers
Data Sources
Heat meters 5000 pcs.
(70000 variables)
Thermal-PowerPlants
60 pcs.(1000 variables)
Heating chambers, Pomp stations
25 pcs. (3000 variables)
ERP, CRM, DB, Accounting
Cor
pora
te L
AN
Business Services
serwerOPC
SCADA, Reports
Presentation ServicesObject Services
Data Services
OPC, SQL,XML/HTML
31
Hydrostatic
P limit
Hydrostatic
Thermostatic
Hydrodynamic
32
SOC
SOC
SB
s
Corporate network
SE
RV
R
View
GIS
View
SCs
Corporate field network
SOCSOC K
Ds
SPM
EC EC EC
TCH
TCH
SYSTEM INTEGRATION
33
NAT
KxxxKxxx
KxxxKxxx
VLANSYM
SOC
SOC
SOCSOC
TCH
TCH
Corporate field network
EC EC EC
KOM
KOM
SQL
SYSTEMS INTEGRATION
View
SE
RV
ER
Corporate network
GIS
View
SB
k
WALL SCREEN
SQL OPC
34
OP
C T
RA
NS
PO
RT
ER
OPC TRANSPORTER
CONFIGURATIONCONFIGURATION
GIS
SMALLWORD
OPC
COMMSERVER
SQL
ORACLE
ST
AT
IST
IC P
RO
CE
SS
OR
TR
AN
SP
OR
T E
NG
INE
SQ
LO
PC
XM
L
35
AUTOMATIC LOAD CONTROL
EC -3 EC -2
K-101
ODBIORY
F1=constF2
F3
UZUPEŁNIANIE
F4
UZUPEŁNIANIE
SUWSUW
K-164
P
PG
G
P
ODBIORY
PO
DZ
IAŁ
P
P P
P P
36
Crash
OP
CS
WS WS
OP
CS
37
Solution
OP
CS
OP
CS
WS WS
REPLACE
38
Solution
OP
CS
OP
CS
WS WS
ISLA
ND
O
F A
UTO
MA
TIO
N
ISLA
ND
O
F A
UTO
MA
TIO
N
ISLA
ND
O
F A
UTO
MA
TIO
N
CONTROL
CONTROL
MUTUALY
ECLUSIVE
39
DEVELOPMENTDEVELOPMENT
APPAPP
INTEGRATIONINTEGRATION
THE MESSAGE IS:
SOCSOC CFISCFIS
HARDWARE
HARDWARE
SOFTWARE
SOFTWARE
TECHNOLOGY
TECHNOLOGY SKILLSSKILLS KNOWLEDGE
KNOWLEDGE
OPC
41
Commserver - Redundancy
Primary Station
Standard solution – worse case
Backup Station
LAN
Wait for failure
Active
SERVICE
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