REDUNDANT, MULTI-PROTOCOL, OPTIMAL OPC SERVER IN D AGGLOMERATION HEAT DISTRIBUTION SYSTEMMariusz Postwww.cas.com.plmpostol@cas.com.plTel. +48 (42) 686 25 47

CONTROL PROCESSd citizens #:1MHeating plants: 3 Total thermal output:2560MWHeat distribution network: ~800km~500milesNumber of nodes:~7 000Production in cogeneration:Hot water,Electric powerSteam

CONTROL OBJECTIVEHEAT STREAM

SUPPLY AREA MANAGEMENT

SYSTEM REQUIREMENTSFunctionalityRemote control of nodesNodes monitoring (incl. environment)Communication network monitoringData archiving (PLC & SQL db)AlarmsIntegration with external IT systemsCommunication25 analogs per nodeUp to 200 nodes (branching, pumping, exchangers)Data latency

FIRST STAGE

COMMUNICATIONVPN

MAINTENANCE COSTS (2002)Assumptions25 analogs/node200 nodesISDN dialing cycle once an hourGPRS transfer equal to 400MHz (4800 bauds)ADSL, TSAT, 400MHz const fee (lump sum)

BASE STATION: HDCR

BASE STATION: HDCR

LOCALIZATIONS AND EXPANDABILITY

RESOURCES ALLOCATIONControl Room (HDCR)OPC

REDUNDANCY AND EXPENDABILITYSMULSKO

REDUNDANCY AND EXPENDABILITYSMULSKO

SERVER

DEVICE COMMUNICATION MESS

DEVICE COMMUNICATION CONTROLSERVERSCANNERCACHEOPC - Interface

PROCESS REQUIREMENTSDIRECTION K101DIRECTION K617

DIAGRAM OF DIRECTION STATES CLOSEDCLOSINGOPENEDOPENINGDONECLOSEDONEOPENACCEPTEDLATENCYSECONDS

WORSE CASE APPROACH

ADAPTIVE APPROACHCLOSEDOPENEDSLOWSLOWFASTSTATE DRIVEN SCANNING POLICYSLOW:POLICYSLOW:POLICYFAST:POLICYSCANNING ON DEMAND

INHERITED PROBLEMSRapid change of loadInability to work on the edgeUnavoidable pressure strokesTime consuming process

COMMON AREASK-231K-1266K-209K-101K-751K-762K-736SMULSKOK-510K-617K-110K-104/30K-164K-175K-104/AK-199K-1014/1K-22K-1023K-637

AUTOMATIC LOAD CONTROLK-101F3REFILLF4SUWSUWK-164PGLOADSEPARATIONPPPPPLOADREFILLAREA 1AREA 2

AUTOMATIC LOAD CONTROLK-101LOADK-164PLOADOPC Connectivity

OPC Transporter

INTEGRATION: MONITORING HDC

PUMPING STATIONS REMOTE CONTROLUNMANNEDhttp://www.cas.com.pl/index.php?p=wdrozenia&sp=0&ssp=soc&lang=en

GISTopology mapInventoryModelingHydraulic calculationSupply area visualizationMore....NOT REAL-TIME SYSTEM

SYSTEM INTEGRATIONSCs

SYSTEMS INTEGRATIONWALL SCREENSQLOPC

WALL SCREEN VISUALIZATION

SYSTEMS INTEGRATION - GIS

PASSIVE OPC SERVERRS485ETHERNETPASSIVEMONITOR

THE MESSAGE IS:

THANK YOU FOR ATTENTION

Zaoenia do systemu:Sterowanie komorami (19 komr - Ich lokalizacja na slajdzie), a waciwie zasuwami w tych komorach ma odbywa si z Dyspozycji ZSC.Monitorowanie i rejestrowanie parametrw technologicznych Wykrywanie i monitorowanie zagroe: wamanie, gaz, zalanie, poar.Moliwo rozbudowy systemu do 200 obiektw.Integracja z istniejcymi systemamiNa etapie oferty dokonalimy analizy technicznych i ekonomicznych aspektw wyboru technologii komunikacyjnej. Szczegy dotyczce tej analizy mona znale na naszych stronach www oraz w materiaach VII Forum z zeszego roku (prezentacja i artyku dr in. Mariusza Posta). Ostatecznie jako podstawowy kana transmisji wybrano kana radiowy w dzierawionym pamie 400MHz z lokalizacj Centralnego Punktu Sieci Telemetrycznej (CPST) w biurowcu ZEC w centrum miasta ktry jest poczony sieci komputerow z ZSC.Tak zdefiniowane zaoenia narzuciy struktur systemu .....

Zaoenia do systemu:Sterowanie komorami (19 komr - Ich lokalizacja na slajdzie), a waciwie zasuwami w tych komorach ma odbywa si z Dyspozycji ZSC.Monitorowanie i rejestrowanie parametrw technologicznych Wykrywanie i monitorowanie zagroe: wamanie, gaz, zalanie, poar.Moliwo rozbudowy systemu do 200 obiektw.Integracja z istniejcymi systemamiNa etapie oferty dokonalimy analizy technicznych i ekonomicznych aspektw wyboru technologii komunikacyjnej. Szczegy dotyczce tej analizy mona znale na naszych stronach www oraz w materiaach VII Forum z zeszego roku (prezentacja i artyku dr in. Mariusza Posta). Ostatecznie jako podstawowy kana transmisji wybrano kana radiowy w dzierawionym pamie 400MHz z lokalizacj Centralnego Punktu Sieci Telemetrycznej (CPST) w biurowcu ZEC w centrum miasta ktry jest poczony sieci komputerow z ZSC.Tak zdefiniowane zaoenia narzuciy struktur systemu .....

Zaoenia do systemu:Sterowanie komorami (19 komr - Ich lokalizacja na slajdzie), a waciwie zasuwami w tych komorach ma odbywa si z Dyspozycji ZSC.Monitorowanie i rejestrowanie parametrw technologicznych Wykrywanie i monitorowanie zagroe: wamanie, gaz, zalanie, poar.Moliwo rozbudowy systemu do 200 obiektw.Integracja z istniejcymi systemamiNa etapie oferty dokonalimy analizy technicznych i ekonomicznych aspektw wyboru technologii komunikacyjnej. Szczegy dotyczce tej analizy mona znale na naszych stronach www oraz w materiaach VII Forum z zeszego roku (prezentacja i artyku dr in. Mariusza Posta). Ostatecznie jako podstawowy kana transmisji wybrano kana radiowy w dzierawionym pamie 400MHz z lokalizacj Centralnego Punktu Sieci Telemetrycznej (CPST) w biurowcu ZEC w centrum miasta ktry jest poczony sieci komputerow z ZSC.Tak zdefiniowane zaoenia narzuciy struktur systemu .....

... ktry z jednej strony dostarcza informacje do dwch (cho moe ich by znacznie wicej) stacji wizualizacji, a niezalenie odpytuje poszczeglne komory.Poniewa serwer (SB Komory) jest zlokalizowany w Dyspozycji ZSC, a CPST musi by zlokalizowany w biurowcu w centrum miasta (kilka kilometrw od dyspozycji) do poczenia ...Radiomodemu z serwerm komunikacyjnym uyto urzdzenia Device Server ktre udostpnia ...port szeregowy komputera poprzez sie komputerow.Ostatnim elementem struktury jest serwer bazy danych Oracle do ktrego zapisywane s parametry technologiczne z komrCzego klient potrzebowa...Ze struktury sieci cieplnej wynika e moe ona pracowa w rnych konfiguracjach. Struktura sieci pozwala na zasilanie poszczeglnych obszarw miasta przez rne rda. Podzia sieci na sekcje zasilania pomidzy poszczeglnymi rdami realizowany jest w magistralnych komorach ciepowniczychNa schemacie wida naturalne granice podziau sieci, niemniej jednak tak naprawd moliwych jest kilkadziesit konfiguracji obszarw zasilania w zalenoci od biecych potrzeb. Telemetric System of Intermediate Pumping Stations Control (STSP) Telemetric System of Intermediate Pumping Stations Control (STSP) is designed for remote monitoring and controlling of unmanned intermediate pumping stations working on main lines in d heating system, from central dispatching room. The intermediate pumping stations are located in the range of 4-6 km from the central dispatching room. Their task is to maintain proper pressure distribution in previously chosen points of the heating net. The task is fulfilled by adaptive control of efficiency and selection of the number of working pumps. Basic system functions are as follows:automatic pumping station start, automatic planned and emergency pumping station shutdown, automatic pressure control - selection of the number and efficiency of pumps, automatic and planned turning on of backup main supply, protection of buildings against burglary or fire, leakage detection in sets of pump units and monitoring of building flooding, fittings control for main line protection in case of any pumping station emergency shutdown, emergency shutdown of pump units in case of increased vibrations or temperature, providing of redundant radio-communication with the central dispatching room, ensuring of an alternative remote control, local and distant monitoring of pumping station work (of hydraulic and electric systems), recording of all-important occurrences and changes of selected work parameters.

SYSTEM INTEGRATIONAll IT systems presented in the article have generally one purpose, i.e. improvement of effectiveness of the heat distri-bution network operation. From the point of view of the user their variety is of no importance and makes use of them diffi-cult. In other words, their construction and functional properties should be maximally integrated and mutually consistent.Considering the design, combining of system functions in one system and, consequently, developing systems with wider functionality create technical and organizational problems. Additionally, it decreases reliability and availability.To meet these two contradictory requirements at the same time, i.e. maximum integration of the functions and keeping the systems size within reasonable limits, it is suggested that a three-plane co-operation of the systems be provided: common visualization, central database and reporting system, making process data values available between the systems e municipal heat distribution network of d (1M citizens) is supplied from three heating plants with total thermal output of 2560MW. Their optimal utilization requires a control system to allow working on common areas. As the system is distributed territorially (about 800km of pipes), safe communication between nodes (automation islands) is critical. Additionally, a great number of nodes (~7000) requires to precede the development of an appropriate system structure by a detailed analysis of the availability, throughput, and connectivity standardization. We have decided to use OPC as a communication engine coupled with VHF network (more...). Because of the propagation limits we have to use several central base station locations. The biggest challenge is to synchronize transmission on one common frequency and provide appropriate level of redundancy and throughput.

In 2002, in the Central Dispatching Room (CDS) there was installed a large-format visualization using solutions pro-vided by Synelec. It consists of a wall display of 4 modules 67", which gives a picture of 273 x 205 cm, with resolution of 2048 x 1536 pixels. The modules are controlled by a dedicated controller (Masterpix - Figure 1). MASTERPIX can take pictures generated by the workstations of the particular systems. There are also installed applications of the clients of the selected systems, including the client of the GIS system.Integration of the systems with the large-size visualization involved solving the problem of communication between systems. At first, for safety reasons, the SOC system was designed as a totally separated one. As it has been already men-tioned, the common purpose corporate network is the communication layer for the GIS system. This network was not con-nected to the field network, also for safety reasons. Only the workstations of the source monitoring system (TCH) were connected to the field network.The basic assumption of the project is that integration will not violate the autonomy of the systems and decrease the level of their separation. To meet this requirement, the VLAN and NAT technologies are used for communication.NAT is used for connecting the corporate network to the field one. Thanks to such a solution, shielding of the field net-work access from the corporate network is achieved. However, access to the corporate network on the side of the field net-work is only possible from a separated virtual segments, so - except for computers operating on this segments - access to the corporate network on the side of the field network is completely separated.Separation of access to the workstations of the SOC system on the side of the field network is provided by connecting them to the separated virtual segments, on which the MASTERPIX controller also operates. However, to make the data of the system available in the field network, there is installed a dedicated application server which reads the data from the workstations and publishes them on the field network (for simplicity purposes it is not shown in the Figure).The database server (ORACLE - Figure 1) of the heat chambers remote control system should serve as a common working basis for all described systems. Such a solution will decrease neither the autonomy nor the safety of their operation because reading and entering into the database can be accomplished for each system independently. Relevant works are at the stage of making assumptions and developing its general outline.The possibility of data exchanging between individual systems is another important issue at the point where they meet. It is a simple task if a uniform software platform has been used for applications of the workstations of the systems de-scribed, e.g. WIZCON. Data exchange between the GIS system and other systems requires modification of the former and introduction of communication mechanisms. Integration is possible as to: archival data included in the ORACLE database, current data rendered available by the communication server.

e municipal heat distribution network of d (1M citizens) is supplied from three heating plants with total thermal output of 2560MW. Their optimal utilization requires a control system to allow working on common areas. As the system is distributed territorially (about 800km of pipes), safe communication between nodes (automation islands) is critical. Additionally, a great number of nodes (~7000) requires to precede the development of an appropriate system structure by a detailed analysis of the availability, throughput, and connectivity standardization. We have decided to use OPC as a communication engine coupled with VHF network (more...). Because of the propagation limits we have to use several central base station locations. The biggest challenge is to synchronize transmission on one common frequency and provide appropriate level of redundancy and throughput.

In 2002, in the Central Dispatching Room (CDS) there was installed a large-format visualization using solutions pro-vided by Synelec. It consists of a wall display of 4 modules 67", which gives a picture of 273 x 205 cm, with resolution of 2048 x 1536 pixels. The modules are controlled by a dedicated controller (Masterpix - Figure 1). MASTERPIX can take pictures generated by the workstations of the particular systems. There are also installed applications of the clients of the selected systems, including the client of the GIS system.Integration of the systems with the large-size visualization involved solving the problem of communication between systems. At first, for safety reasons, the SOC system was designed as a totally separated one. As it has been already men-tioned, the common purpose corporate network is the communication layer for the GIS system. This network was not con-nected to the field network, also for safety reasons. Only the workstations of the source monitoring system (TCH) were connected to the field network.The basic assumption of the project is that integration will not violate the autonomy of the systems and decrease the level of their separation. To meet this requirement, the VLAN and NAT technologies are used for communication.NAT is used for connecting the corporate network to the field one. Thanks to such a solution, shielding of the field net-work access from the corporate network is achieved. However, access to the corporate network on the side of the field net-work is only possible from a separated virtual segments, so - except for computers operating on this segments - access to the corporate network on the side of the field network is completely separated.Separation of access to the workstations of the SOC system on the side of the field network is provided by connecting them to the separated virtual segments, on which the MASTERPIX controller also operates. However, to make the data of the system available in the field network, there is installed a dedicated application server which reads the data from the workstations and publishes them on the field network (for simplicity purposes it is not shown in the Figure).The database server (ORACLE - Figure 1) of the heat chambers remote control system should serve as a common working basis for all described systems. Such a solution will decrease neither the autonomy nor the safety of their operation because reading and entering into the database can be accomplished for each system independently. Relevant works are at the stage of making assumptions and developing its general outline.The possibility of data exchanging between individual systems is another important issue at the point where they meet. It is a simple task if a uniform software platform has been used for applications of the workstations of the systems de-scribed, e.g. WIZCON. Data exchange between the GIS system and other systems requires modification of the former and introduction of communication mechanisms. Integration is possible as to: archival data included in the ORACLE database, current data rendered available by the communication server.