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

3

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

7

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

8

Punkt krytyczny

Punkt krytyczny

Punkt krytyczny

Punkt krytycznyPunkt krytyczny

Łódź

Śródmieście

Janów

Chojny

Smulsko

Teofilów

Radogoszcz

Dąbrowa

9

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

10

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

14

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

16

Commserver - Redundancy

Commserver solution

SERVICE

Standby

ActiveStandby

Active

Standby

Active

Fail

17

WS

WS

ES

DEVICE COMMUNICATION MESS

18

DEVICE COMMUNICATION MANAGEMENT

SERVER

SC

AN

NE

R

CA

CH

E

OP

C -

Inte

rfac

e

WS

WS

ES

F( ) ?

19

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

21

ADAPTIVE APPROACH

CLOSEDCLOSED OPENEDOPENED

CLOSINGCLOSING

OPENINGOPENING

SLOWSLOW SLOWSLOWFASTFAST

STATE DRIVEN SCANNING POLICY

SLOW:POLICY SLOW:POLICYFAST:POLICY

SCANNING ON DEMANDSCANNING ON DEMAND

22

Commserver – SCANNING ON DEMAND

Normal state – slow scanning

23

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

25

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

26

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

29

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