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Process Analyzer Connectivity Initiative (ConnI) A Status Report

Process Analyzer Connectivity Initiative (ConnI) A Status Report. Ron O’Reilly Dow Chemical Canada Inc. Fort Saskatchewan, AB Canada. Peter van Vuuren ExxonMobil Chemical Baytown, Texas USA. Topics. Functional Domain and Connectivity Model for Process Analyzer System - Overview

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Process Analyzer Connectivity Initiative (ConnI) A Status Report

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  1. Process Analyzer Connectivity Initiative (ConnI) A Status Report Ron O’ReillyDow Chemical Canada Inc.Fort Saskatchewan, ABCanada Peter van VuurenExxonMobil Chemical Baytown, TexasUSA

  2. Topics • Functional Domain and Connectivity Model for Process Analyzer System - Overview • Measurement Domain • DCS Domain • Model - O&M Domain • Model - Enterprise Model • A Summary

  3. ConnI recognizes that a process analyzer isnot a stand-alone entitybut has only added value if throughconnectivityit is anintegralcomponent of several relatedsystem domains: Connectivity Role • Measurement domain: integrated with other analyzers • DCS domain: DCS is itsprimary customer • Analyzer Operations/Maintenance domain: Support system for reliable operation and effective user interfaces • Enterprise domain: Must allow remote access and support

  4. Hierarchical/Domain* Model for Process Analyzer System - Overview Level 4 Enterprise LAN EnterpriseDomain Safety Level 3 LAN O&MDomain DCSDomain Control/Optimization c-LAN AnLAN  Environmental Level 2 LAN = Field LAN Primary Data Path > Requires Maximum Integrity/Reliability Secondary Data Path > Requires HighIntegrity/Reliability SAM Level 1 SensorBus (CAN) Measurement Data(Validated)Status/Change Info DCS Data +:Raw Data/Calibration/SQCDiagnostics/Alarms eSAM  Limited Control Functions MeasurementDomain Configuration DataAll Control Functions * Functional Domains NOT Computer Domains L4 L3 L2 L1 L0

  5. Hierarchical/Domain Model for Process Analyzer System - Measurement Domain Ent DCS O&M  Level 1 Bus (CAN)  Measurement SAM SAM Level 1 SensorBus (CAN)  eSAM eSAM  MeasurementDomain • Modular Smart Sampling System(NeSSI) • Sample, Condition and Validate Process Sample • Multiple Sensors (may be Physical and Analytical) • Level 1 Sensor Bus (CAN -based SDS or DeviceNet) Small Footprint Configuration via Flash Memory Existing and Mature Technology - Inexpensive Components CAN-based communications already in use by Major Suppliers • Future Goal is Wireless Communications (NeSSI III)

  6. Hierarchical/Domain Model for Process Analyzer System - Measurement Domain Ent DCS O&M  Level 1 Bus (CAN)  Measurement SAM SAM Level 1 SensorBus (CAN)  eSAM eSAM  MeasurementDomain • Sensor/Actuator Manager (SAM) • SAM is a Sampling System ControllerManages all Sampling System Functions and DiagnosticsCollects and Validate Sensor Information (Analytical Sensor information Converted by Analyzer Controller) • Examples of Functions:Responsible for Stream Sequencing (Valve Actuation)Control Sampling System Heating/CoolingMeasures all physical Properties of Sample (e.g.. T,P,F)Collects Maintenance & Diagnostic Information(SAM is key to successful Preventative Maintenance System) • SAM can be a Stand-alone Level 2 Controller Device communicating via the Level 2 LAN with it’s Host Controller • SAM Functionality can be embedded in an Analyzer Controller (e.g. GC Controller) • Standardized Communications between Sensors and SAM of critical importance if NeSSI Sampling systems are to be successful • Connectivity Issues:CAN-based specification (2002/2003)SAM/Host Analyzer Controller Functional Specification • SAM is likely a WIN CE device which can also support OPC Communications between SAM and Host Controller

  7. Hierarchical/Domain Model for Process Analyzer System - Measurement Domain Ent DCS O&M  Level 1 Bus (CAN)  Measurement SAM SAM Level 1 SensorBus (CAN)  eSAM eSAM  MeasurementDomain • Analyzer Controller • Responsible for the Measurement and Overall Validation of Result(s)Support and Validation of Sampling System via SAM (Embedded or Remote) • Update DCS System via OPC Gateway Server or other Datalink Types (OPC Server may be Embedded) • Update Short Term Data Server • Support User Interface at Workstations (Multiple User Interfaces from Different Analyzer Controllers must co-exist) • Scalable Platforms (WinCE to Windows XP/2000) • Connectivity Issues:Protocol for Updating OPC DCS Gateway ServerUser Interface Communications ProtocolsDatabase Server Protocols

  8.   Raman FTNIR GC GC Proposed Connectivity Model for Measurement Domain Diversity of Analyzer Devices that makes up the Measurement Domain Anlzr Level 2 FLAN Spectral Fiber (Private IP Addresses) GP Area - Control/Analyzer/RIB Room Fiber -optic link Fiber -optic link Field Anlzr Level 2 FLAN AnalyzerControl SAM SAM SAM GC  GC GC Anlzr Level 1Sensor Bus (CAN) Sampling Systems EmbeddedSAM

  9. Define the Physical Layers for Level 1/2/3* Level 1 : CAN bus* Level 2/3: Ethernet TCP/IP (Industrial) Identify Compatible High-level Communication Protocols (peaceful co-existence on same workstations, servers etc.)* OPC* HTTP* Fieldbus etc. Define Functional requirements for Data Server, Workstations and Long Term Historian Define Requirements for Analyzer-DCS Data Link Interface* Draft Specification posted on CPAC ConnI website ConnI Goals

  10. Hierarchical/Domain Model for Process Analyzer System - DCS Domain Ent  SAM FTNIR  eSAM DCS O&M Long Term Historian Level 1 Bus (CAN) Measurement DCSDomain Analyzer GatewayOPC Server(AGS) OPC ClientBridge(CB) EmbeddedDCS OPCClient(EDC) EmbeddedAnalyzer OPC Server(AES) DCS OPC Server Not showing Operator Consoles

  11. Hierarchical/Domain Model for Process Analyzer System - DCS Domain Ent  SAM FTNIR  eSAM • How do we “stitch these together? * Ethernet & TCP/IP • What information do we exchange? * Draft OPC DCS/Analyzer Datalink * Soliciting Comments * Soliciting Endorsements * Testing Underway or Planned with Several Process Control and Process Analyzer Vendors DCS O&M Level 1 Bus (CAN) Measurement DCSDomain EDC CB AGS AES Not showing Operator Consoles

  12. Hierarchical/Domain Model for Process Analyzer System - DCS Domain Ent  SAM FTNIR  eSAM • DCS Analyzer OPC Client • DCS Analyzer OPC Client:* Setup and Configuration based on Analyzer OPC Server Database* Should be based on OPC Standard 2.0* DCS Client linked to DCS Specific OPC Server* Communication with OPC Analyzer Server via Ethernet TCP/IP • Configuration of OPC Client should be based on using standard OPC 2.0 Configuration Software e.g., “subscribing” to the individual analyzer OPC data elements such as “Analyzer Status” • The DCS Client can be implemented as:* Embedded DCS Client (integrated with the DCS OPC Server and supported by the DCS Supplier)* Client Bridge i.e., “Double Headed Client” - Presents itself as a Client to the Analyzer OPC Server - Presents itself as a Client to the DCS OPC Analyzer Server - Typically provided/supported by a Third Party DCS O&M Level 1 Bus (CAN) Measurement DCSDomain EDC CB AGS AES Not showing Operator Consoles

  13. Hierarchical/Domain Model for Process Analyzer System - DCS Domain Ent  SAM FTNIR  eSAM • Analyzer OPC Server • Implemented either as a “Gateway” (AGS) or Embedded Server (AES) • TCP/IP - OPC is currently the protocol of choice for communications between computers in the DCS World - in process of adapting it as the basis for an Analyzer/DCS Datalink • Progress:Preliminary Specification Developed:* Client/Server Topologies* Addressing Scheme* OPC Server Content Summarized Later • Status/Plans:* Draft specification posted on CPAC ConnI website 2Q02* Complete Specification in 1Q03 as part of ConnI effort* Testing to continue 3Q02 - 2Q03 (Several Control System/Analyzer Vendors)* Solicit endorsements from end-users, analyzers suppliers and DCS vendors DCS O&M Level 1 Bus (CAN) Measurement DCSDomain EDC CB AGS AES Not showing Operator Consoles

  14. Hierarchical/Domain Model for Process Analyzer System - DCS Domain Ent  SAM FTNIR  eSAM • DCS/Analyzer OPC Datalink Specification • Draft Specification posted for comments on CPAC ConnI website • Complete Final Specification in 1Q03 as part of ConnI effort • Continue testing with several Process Control/Process Analyzer Vendors • Solicit endorsements from other analyzer and DCS vendors • Specification Addresses Three Key Functions: • * Client/Server Topologies* Addressing Scheme* OPC Server Content/Failure Recovery DCS O&M Level 1 Bus (CAN) Measurement DCSDomain EDC CB AGS AES Not showing Operator Consoles

  15. OPC Datalink Specification -Analyzer Operations as Event Driven Functions Initialization Data Status Change Fault Recovery Specification allows for Bidirectional control:DCS Console Operator can Request Status Change e.g.* Start/Stop an Analyzer* Enable/Bypass a Stream* Change the Sequence of Streams to be Analyzed

  16. 1 1 1 1 1 2 n Summary of Possible Analyzer Controller and Stream Configurations Detector/Probe Streams = STRM Components = COMP Configuration Types Controller CAP Examples TYPE 1a Single ControllerSingle CAP Single Detector/Probe/Stream Single Component pHConductivity OxygenAutotitrator TYPE 1b Single Controller Single CAP Single Detector/Probe/Stream Multiple Components PhotometerSimple GC TYPE 2a Single ControllerSingle CAP Multiple Detectors/Probes/Streams Single Component Panametrics GC RegularGC Master/Slave FTIRRAMANMass Spec TYPE 2b Single Controller Single CAPMultiple Detectors/Probes/Streams Multiple Components TYPE 3 Single Controller Multiple CAP Multiple Detectors/Probes/Streams Single/Multiple Components GC Master/Master FTIRRAMAN

  17. Proposed OPC Datalink Specification - Address Hierarchy

  18. Hierarchical/Domain Model for Process Analyzer System - O&M Domain Ent  SAM  eSAM DCS O&M Level 1 Bus (CAN) Measurement • Analyzer Workstation • Primary Maintenance/Operations Window into Process Analyzer System • Key Functions:* Upload and Download of Analyzer Configuration/Methods* Access of Real-time Diagnostic/Analyzer Data @ Analyzer* Access of Diagnostic/Analyzer Data @ Analyzer Server* Access and Configuration of SQC Data/Run-time Rules @ Server • Specification Work to begin in 2003 O&MDomain AnLAN

  19. Hierarchical/Domain Model for Process Analyzer System - O&M Domain Ent  SAM  eSAM DCS O&M • Analyzer Server • Short Term ( ~ 1 month(?)) Data Archive* Raw Data for all assigned Analyzers* Operational Data Storage (Methods/Configurations etc.)* Primary Database for Workstation Access * Serves as Front-end to Long-term Data Archive • Connectivity/Specification Issues:* Database Type(s)- ODBC vs. Others* Co-existence of Analyzer Data from Different Vendors* Communications Protocol for Data Exchange between Analyzer and Server • Specification Work to begin in 2003 Level 1 Bus (CAN) Measurement O&MDomain AnLAN

  20. Hierarchical/Domain Model for Process Analyzer System - O&M Domain Ent  SAM  eSAM DCS O&M • Analyzer/DCS Long Term Data Archive • May be located in O&M Domain or DCS Domain (see DCS Domain functions) • If located and supported in the O&M Domain, typically would only store Analyzer Data • May require translation software to Update Long Term Archive from Short Term Analyzer Archive (See Analyzer O&M Domain) Level 1 Bus (CAN) Measurement O&MDomain AnLAN

  21. Work-station Work-station FTNIR Raman Proposed Connectivity Model - DCS Datalink Client/Server Topologies One of many ways a system can be stitched together Plant LAN IntraNet OPC ClientBridge(CB) LEVEL 3/4Router Analyzer GatewayOPC Server(AGS) PDC Historian EmbeddedDCS OPCClient(EDC) DCS OPC Server Server/ Workstations DCS Level 2 LAN (TDC=LCN) E.g. Cisco2950 VLANSwitch/Router EmbeddedAnalyzer OPC Server(AES) Anlzr Level 2 FLAN (Private IP Addresses)

  22. ConnI Status Report: Summary • Draft OPC DCS/Analyzer Datalink specification published for comments* Testing Planned or Underway with Several Process Control/Process Analyzer Vendors • Solicitation of Endorsements/comments/changes from analyzer suppliers/DCS vendors and end-users underway • Overall Architecture well in place - Generic Functional Specification aimed for 2003 • Functional specification for NeSSI Sensor bus and SAM (part of NeSSI Gen II specification) to be published soon (NeSSI Website) • Prototype Proof of Concept Apparatus (POCA) systems being developed by Honeywell* Based on IS CANbus* Will allow for testing of SAM functionality

  23. FINI

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