how top plant managers avoid real-time chaos
DESCRIPTION
To view on-demand webcast:http://www.embedded-know-how.com/tools-a-software-main/article/44-tools-software/1192-leveraging-continuous-real-time-automation-data-as-a-business-asset.htmlAchieving true real-time collaboration between the IT business systems back end and the plant control front end is just not happening – yet. Those that have tried have hit a real-time wall. The competitive business benefits for those that break through this wall include fixed and variable asset cost minimization, predictive maintenance capabilities, and empowerment of operational staff with up-to-date business objectives and business IT staff with timely asset performance metrics.But, when you connect the two disparate systems, the operational plant managers suspect the IT systems will undermine their plant reliability, and the IT managers knows that the data deluge from the operational side will swamp their network.What if you could adopt an integrated infrastructure that guarantees no single point of failure for the operational systems?What if your DCS or PLC data could be made immediately available to your Business Intelligence IT systems at a rate they can deal with?TRANSCRIPT
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Your systems. Working as one.
How Top Plant Managers AvoidReal-Time Chaos
Webinar – June 14th 2012
Geoff RevillReal-Time Innovations
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Agenda
• Brief Company Intro• IT and Control Systems Collaboration – Benefits
sought• What’s blocking access to these business
benefits? - The RT Wall• How to use the RT Wall as a foundational SoS
Element• The Solution – A Real-Time ESB• Summary
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About RTI
• Market Leader– fast, scalable communications software for real-time
operational systems and IT & Business Systems Systems Integration
• Pedigree– 20 year+ history in
• High-performance highly scalable networking & control
• Middleware & Tools
• Standards Leader– OMG Board of Directors– Market leader in DDS (Data Distribution Service)
• Maturity Leader– 15+ years of commercial availability– U.S. DoD Technology Readiness Level (TRL) 9
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ROI Example – JBC-P – Blue Force Tracker
04/13/2023
Legacy design:• Custom, proprietary• 2-8 years to develop• 1.5m lines of source code• 12,000 tracks• 11 servers w/88 cores• Poor reliability and uptime
DDS design:• 100% standards based• Proof of concept in under a week• 50k lines of source code• 250,000 tracks• 80% of a single core• Full redundancy
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IT & Operational Collaboration
Business Centric DecadeShift from enabling technology
to using
Available and proven Technologyto improve Business Performance
throughOperational Efficiency
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• Business Goals– Return on Assets– Continuous Improvement– Flawless Execution– Increased Automation– Total Cost of Ownership– Increased Commonality of
Infrastructure– Reduce Barriers to
Information
• Business Benefits– Operational Effectiveness– Asset Utilization– Minimize Variable Costs– Reduce Downtime– Preserve Capital Assets
Business Centric
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The Highest Barrier to Information?
TIME
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Collaborative Production Management
• To be delivered by Collaborative Process Automation Systems (CPAS)– Single, unified environment for the presentation of
information to the operator as well as present information in context to the right people at the right time from any point within the system
– ARC Advisory Group
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CPAS
• As defined by ARC Advisory Group– extraordinary performance– continuous improvement– proactive execution– common actionable context– single version of the truth– automate everything that should be automated– facilitate knowledge workers– common infrastructure based on standards
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The shift to CPAS
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Example: Predictive Maintenance
• Is it solely an Operational Control issue?– What about the changing trade off between risk of
an asset failing versus cost of maintenance?– What about the changing nature of customer
supply demands versus maintenance schedules?– How do your business systems get informed
immediately of the consequence of an operational asset failure?
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Different Realities Operational Systems IT Systems
Architecture Decentralized (peer to peer) Centralized data center (hub and spoke)
Speed “Real world” (physical processes) Human
Data flow Event-driven: sensors, alarms, commands. Extremely time critical.
Transactional, non real-time
Platforms Tiny embedded or mobile systems through powerful servers
Powerful servers
Lack performance and scalability
Lack integration power
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OT and IT Developers think differently
• Peer-to-peer• Events, alarms, sensor
readings, status updates• Pub-sub pattern
• Client-Server• Remote Method
Invocation• Request-Reply pattern
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The Real-Time Wall Operational Systems IT Systems
Architecture Decentralized (peer to peer) Centralized data center (hub and spoke)
Speed “Real world” (physical processes) Human
Data flow Event-driven: sensors, alarms, commands. Extremely time critical.
Transactional, non real-time
Platforms Tiny embedded or mobile systems through powerful servers
Powerful servers
Lack performance and scalability
Lack integration power
R
T
W
A
L
L
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Collaboration drives Scale!
• More things producing and consuming data
• Greater volume of data• System of systems
integration
• The Software Architecture must enable change in scale
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How do we take down the RT Wall?
• What if….?– Every application could dynamically define it’s real-
time requirements to the infrastructure?– the infrastructure could sustain a quality of service
contract between every communicating entity?– the infrastructure could act like a database and
represent system state in real-time?
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Turn the RT Wall into a System SW Foundation Operational Systems IT Systems
Architecture Decentralized (peer to peer) Centralized data center (hub and spoke)
Speed “Real world” (physical processes) Human
Data flow Event-driven: sensors, alarms, commands. Extremely time critical.
Transactional, non real-time
Platforms Tiny embedded or mobile systems through powerful servers
Powerful servers
Lack performance scalability
Lack integration power
F O NOITADNU
BSETR
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Using the RT Wall as a Foundational Infrastructure
• IT systems should be able to react to critical real-time Operational Control state changes
• OT systems should be able to continuously deliver analyzable metrics for business use
• DATA is the Foundational Building Block– IT systems architect around it with their DB’s– OT systems architect around it for state changes
• Free Flow of Information is the Goal
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Maintaining STATE across IT & OT
• System STATE is a function of DATA• Each Application’s need to understand STATE is
different– Only needs to know a small subset of system STATE– Has differing requirements and authority for
system STATE change• Any Application can contribute to system STATE
change• System STATE is the “single version of the truth”
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Where is system STATE Maintained?
• Where the DATA is– IT in a Database– Operational Control – its on the BUS
• But the ‘bus’ is also a means to access the DB
• For CPAS and Collaborative Systems– Maintain State on the Bus in order to serve IT and
Operational Control systems• STATE needs to be maintained on a DATABUS
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Where is STATE Maintained?
RTI Connext – Common Data Infrastructure
Traditional ESB
Process Automation Systems
HMI Control I/O
Plant Business Operations
Information Technology (IT)
Operational Technology (OT)
Production Management
MobileDevices
Data/Conf ig Alarms
Co
nvergence
Integratio
n
Dynamic Discovery
Peer-to-Peer
Publish/Subscribe
Global Data Access
Quality of Service
ToolsSOA Architecture Reliable Multicast
Full Redundancy
Alig
nment
Gartner
DATABUS – SUSTAINS SYSTEM STATE
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The Need for App Defined QoS
• De-Couple Application Real-Time needs from the infrastructure– Infrastructure can independently evolve in line
with broader distributed systems requirements• Create loose bindings between applications
– New Apps ‘discover’ the system’s ability to serve it’s system state needs at run-time
• Connect to the DATABUS not to another Application
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Connext Foundation: the RTI DataBus™
• Data centric– Structured, accessible data– Like a database for moving
data• Independent modules
– Supports SOA– Supports RT Applications
• Plug and play flexibility– Like a hardware bus
• Peer-to-peer performance– Like streaming protocols
• Standards-based interoperability
– Like TCP/IP
Data-Centric Messaging Bus
Scalable, high performance, reliable infrastructure
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RTI Connext™: A Next Generation Infrastructure
RTI DataBus™
ConnextMicro
Pub/Sub API
Small Device Apps
ConnextDDS
Pub/Sub API
DDS Apps
ConnextMessaging
Messaging API
General-Purpose Real-Time Apps
ConnextIntegrator
Adapters
Discrete OT & IT Apps/Systems
Administration
Monitoring
Logging
Recording
Replay
Federation
Transformation
PersistenceVisualization
Common Tools and Infrastructure Services
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Connext Messaging
Example—Production System
PLC
ConnectorMicro, linked in
process
PLC
ConnectorMicro, linked in
process…
SCADA Application
ConnectorLinked in process
DDS API
Factory Floor
Connext Integrator
ConnectorStandalone deployment
ERP System
ConnectorStandalone deployment
Web Service
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A Real-Time ESB for CPAS
“The benefits that come from managing Information Technology (IT) and Operational Technology (OT) convergence, alignment and integration include optimized business processes, enhanced information for better decisions, reduced costs, lower risks and shortened project timelines.”
• – Gartner
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RTI started here – Naval C4I
• C4I
• Command
• Control
• Communications
• Computers
• Intelligence
• Fully data-centric design
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RTI Connext Proven here…..• RATP
• Transport control systems
• WAN and LAN Integration• Multiple Platform types
• PC Windows• Linux• Solaris• Instrumentation
• Major Issue with Legacy System integration
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RTI Connext Used here…..
• The ATLANTIDA consortium• 34 collaborating
organisations• Researching next
generation ATC• Massive Scalability
Challenges• Huge Collaboration
Challenges
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RTI Powering Next Gen SCADA
• Siemens Windpower• Challenges
– Increase sample to 100Hz– Manage up to 500 turbines
• Existing infrastructure failed– Failed to integrate IT/OT systems– Could not deliver performance at
scale• Benefits of control vs. monitoring
– Predictive & preventive maintenance– Smart diagnostics – improve
availability and efficiency– Production planning– Continuous performance monitoring
and tuning of turbines
RTI Connext melds distributed performance with IT business intelligence
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04/13/2023 © 2012 RTI • COMPANY CONFIDENTIAL 31
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