model based soft-sensors based on opc unified architecture · model based soft-sensors based on opc...
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Model based soft-sensors based on Model based soft-sensors based on OPC Unified ArchitectureOPC Unified Architecture
Paolo Greppi, consultant, 3iP, Italy
POWER-GEN Europe 2010 ConferenceJune 10th, 2010
Amsterdam
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Presentation outline
● The problem● Old solution● New solution● An example● Future outlook
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The problemThe problem
Power Plantby Grandwazoo
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3 stories
1) supplier of plants packages
2) automation supplier
3) operating company
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Story 1: supplier of plants packages
● Provide fully-automated, self-diagnostic, self-optimizing, "intelligent" units
● Adapt and customize the package units to the ever-changing specifications with minimal effort and risks
● Make the package units easier to deploy by adapting to the customers' industrial information technology infrastructure
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Story 2: automation supplier
● Flexible design: react to project changes● Diverse environment: open standards● Maintainability: follow seamlessly the changes
during the operation phases ● Avoid risky reconfiguration or manual
adaptation of custom interfaces
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Story 3: operating company
● Adapt to load changes● Handle day-night fluctuations in the electricity
price ● Handle feedstock changes: variable-by-design
feedstocks such as biomasses, but fossil fuels change quality continuously too
● Adjust the production mix the demand (cogeneration or trigeneration)
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flexibilityadaptintegration
low-risk
market
optimize
self-diagnostic
intelligent
customize
smartunmanned operation
change
value
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Old solutionOld solution
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Protocols & interfaces
● 4-20 mA● SMART● HART● Ethernet● Sattbus● Modbus● Profibus / Fieldbus
● EDAS● CIP● CIM-IO● IEC 870-5-101/104● http / https● ODBC● WCF● Classic OPC
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Classic OPC
● Classic OPC is a set of de-facto standards
http://www.opcfoundation.org
● For interfacing between process automation (SCADA, PLC, DCS) and the rest of IT
● Time span: 1996 – 2005● Based on COM technology (Microsoft, 1993)
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Resulting industrial IT architecture
From an IBM whitepaper
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New solutionNew solution
Hellisheidi byThinkGeoEnergy
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OPC UA (Unified Architecture)
● OPC UA (Unified Architecture) is a single de-facto standard, evolution of Classic OPC
http://www.opcfoundation.org
● Time span: 2006 - ...● Based on SOA● Platform-independent (non-Microsoft specific)● Object-oriented● Semantic: domain-specific information models
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SOA (Service Oriented Architecture)
before SOA after SOA
From an IBM whitepaper
business process
business process serviceservice interoperable
software moduleinteroperable
software module
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MainframeMainframe
devices porta
bles desktops servers clusters m
ainframes
devices porta
bles desktops servers clusters m
ainframes
OPC UA: platform-independent
PortablesPortables
DesktopDesktopPCPC
ServerServer
ServerServerClusterCluster
EmbeddedEmbeddedSystemsSystems
ControllersControllers
Standard internet protocols allow cross-platform communication
Multiple OPC APIs•C/C++•JAVA•Microsoft .NET
Profiles used to define subsets of functionality for different use cases
From an OPC Foundation presentation
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OPC UA object oriented: types
Object Type
Variables ___ ___ ___
Methods ___() ___() ___()
Events
From an OPC Foundation presentation
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OPC UA object oriented: instances
Object Type
Variables ___ ___ ___
Methods ___() ___() ___()
Events
Object Instance
Variables ___ ___ ___
Methods ___() ___() ___()
Events
From an OPC Foundation presentation
Object Instance
Variables ___ ___ ___
Methods ___() ___() ___()
Events
Object Instance
Variables ___ ___ ___
Methods ___() ___() ___()
Events
Object Instance
Variables ___ ___ ___
Methods ___() ___() ___()
Events
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OPC UA: architecture
OPC UA Base Services
Vendor Information Model
DA A&C HA Progs
Domain-specific Information Model
From an OPC Foundation presentation
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● Domain-specific information models for:● device information● analyser devices● plant operation and maintenance● batch control● PLC programming● process simulation capabilities ?
OPC UA: semantic
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Swept blades by Bleuchoi
An exampleAn example
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Soft sensors
Soft-sensors = replace real sensors with virtual, calculated results
● Model-driven - first principle models ● Data-driven - based on raw data manipulation
● Principle Component Analysis (PCA)● Partial Least Squares (PLS)● Artificial Neural Networks (ANN).
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The soft-sensor of the example
● gas-chromatograph measures the composition of a a material stream composed of short-chain hydrocarbons
● Soft-sensor computes:● Lower / higher heating value and Wobbe-Index;● LEL / UEL (lower and upper explosive limits) and
LOC (limiting oxygen content);● Density, compression factor and temperature /
pressure dew-point and bubble-point with an equation of state specific for Natural Gas (GERG-2004)
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LIBPF: LIBrary for Process Flowsheeting
● Modular Software Development Kit (SDK) for process flowsheeting
● Object-oriented C++ library:● Components, physical properties, phases, streams,
unit operations and flowsheets● Tools: solvers, input/output, object persistency,
communication interfaces
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Classic OPC soft sensor
● OPC DA 2.0.4 client● Placeholder tags have to be
defined in the OPC server● Configuration via XML file● Start / stop as an operating
system service
Calculation kernel
OP
C d
atal
ink
DCS
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OPC UA process simulation information model
OPC UA node types from LIBPF objectsBaseObjectType
modelBase
edgeBase vertexBase
stream
stream_VL
stream_VL_eos<pengrobinson> stream_VL_eos<pcsaft> stream_VL_eos<gerg2004>
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OPC UA soft sensor prototype
LIBPF objects are exposed as OPC UA nodes at runtime
Flowsheet object instance
Method can be actioned on the objectUnit operation object instance
Quantity with engineering unit object instance
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OPC UA soft sensor features
● Runs on both Windows and Linux● Could even be integrated directly into the
device (gas-chromatograph, fiscal meter)● No configuration files● The configuration can be performed using any
3rd party OPC UA client, thanks to the discovery and browsing capabilities
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Future outlookFuture outlook
RWE Weisweiler by glasseyes view
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Future work for us
● Complete the prototype, implementing additional OPC UA interfaces:● the node creation interface: clients can browse the
hierarchy of available types known to the server, and request that one of them should be instantiated at run-time
● the state machine information model: clients can configure the valid / invalid states and their triggers
● the program interface: clients can start / stop soft sensors individually without starting / stopping the service / daemon
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Future work for the community
● Agree on a domain-specific information model for on-line application of process models on top of OPC Unified Architecture stack:● Process modeling objects: Components, phases,
streams, unit operations● On-line modeling applications: Soft sensors,
process simulation, advanced control, model predictive control, plant-wide mass balance reconciliation, operator training
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OPC Unified Architecture (UA): a new platform-independent standard for interoperability
between enterprise information systems and industrial automation
OPC UA could reshape the automation industry and the business models in the process
simulation and optimization and in the real-time process optimisation and training sectors