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Case Study: Papeterie de Mandeure, France

French paper company, Papeterie de Mandeure, accesses data from their OT system and feeds it to their IT system and MES, using the DataHub.

AWS Outage Calls Attention to Hybrid Cloud

At the end of February Amazon Web Services (AWS) slowed to a crawl for about four hours, causing a major loss of service for hundreds of thousands of websites in North America.  Sites with videos, images, and data files stored on the AWS cloud server suddenly lost much or all of their content, and/or shut down altogether.

After the initial weeping, moaning, and outrage died down, a lively discussion ensued among IT technicians, managers, and concerned citizens on to how to deal with this kind of incident in the future.  The comment section on a story at The Register gives a sample of the kinds of ideas put forward, and there is a clear consensus on a number of them.  Most experts agree that the occasional service outage is one of the inherent risks of using the Internet and cloud services, and that if you need high reliability for your data, you’d better have some kind of redundant or backup solution.

There are normal, accepted ways of building redundancy into a data communications system, including IoT and cloud applications.  One approach mentioned frequently is “hybrid cloud“, a public and a private cloud running simultaneously.  A public cloud is service offered to anyone, typically by a company for paying customers, like AWS.  A private cloud is a service operated and maintained by an individual or company for its own internal use.  To achieve redundancy for AWS in this past outage, a private cloud would have been up and running with a copy of all the company’s data and software, the same as AWS, but just not online.  When AWS stopped serving data, the system would have automatically switched to the private cloud, and someone using the website would not even have noticed.

This is how it works in theory, but building and maintaining a hybrid cloud system that can perform this kind of redundant operation is no small task.  Depending on the level of data and functional replication, in addition to the speed of error detection and  switch-over capability, the hybrid site could cost as much, or even more than the cloud site.  Companies considering such an option would need to do a cost/benefit analysis, based on their specific circumstances.

For Industrial IoT applications a hybrid cloud approach to redundancy may be useful.  Although low-level process control systems should typically not be dependant on the Internet or cloud services, companies who use the IIoT for process monitoring, data collection, or high-level control applications may find it worthwhile to maintain a hybrid cloud.

Skkynet’s SkkyHub service lends itself particularly well to hybrid cloud solutions.  It is possible, and not very difficult, to run a replica system on an in-house server, using the DataHub. Although the DataHub is different from SkkyHub in some respects, for the primary task of data connectivity the two function in an equivalent way.  Readers interested in trying this out are encouraged to contact Cogent for technical tips to ensure a secure and robust implementation.

Case Study: Mukhaizna Oil Field, Oman

Optimizing OPC connections with the DataHub

In 2005 the Sultanate of Oman issued a Royal Decree to develop the giant Mukhaizna oil field covering a vast expanse of desert in the center and south of the country. A major worldwide producer of oil, natural gas, and chemicals was given responsibility for developing the Mukhaizna field, and from 2005 to 2008 oil recovery rates were increased by more than 600% through the use of a steam-assisted gravity drainage process. As each year goes by, the company makes every effort to continuously upgrade technology and improve productivity of the field.

Eight separate production facilities in the Mukhaizna oil field are using Rockwell PLCs, linked to Iconics HMI/SCADA systems for data visualization and operator control. This data collection and distribution mechanism worked well when first implemented, but as the number of data points increased over time it became clear to the project engineers that they needed a way to improve performance. So they began to look for a way to streamline the data flow. The solution they found not only performed well, but it created other, significant opportunities for real-time data integration.

Software Toolbox logo

At each of the eight locations, Rockwell PLCs are connected to an Iconics Genesis32 HMI through an OPC server. The TOP Server OPC server from Software Toolbox (Cogent’s Sales and Technical Partner) gathers data from as many as 20 PLCs, and feeds that to the HMI. As new equipment was brought online, the number of tags in the system approached 30,000, which is normally not a problem for TOP Server. But something was clearly different with this system and it became apparent that some sort of optimization was necessary.

Optimization

The problem was that the HMI was forcing the TOP Server to make device reads, which bypassed TOP Server’s optimization at the device level. Device reads by an OPC client are intended to cause the OPC server to get the information and reply back to the OPC client before doing anything else. While these types of calls are useful in critical situations, all communication optimization has to be done through full system design. The HMI was also requesting updates on groups of OPC tags as it needed them, but these groups were often in a different logical order than how the data points were represented on the PLC. The combined effect was forcing the TOP Server to make more requests for smaller amounts of data, slowing the data-gathering process.

“The OPC server seemed to be dying under the load,” said Juan Munoz, Project Manager for the Mukhaizna oil field project. “Even at rates as low as once per second, it was difficult to scan 30,000 tags, and get the critical data changes that we needed.” Based on his experience with the TOP Server in other projects, Mr. Munoz knew the server itself was not the issue, so he searched the Software Toolbox website for a solution and found the Cogent DataHub®.

The DataHub, developed by Cogent Real-Time Systems (a subsidiary of Skkynet), is a highly optimized data integration tool. It is a memory resident real-time database that provides quick, reliable and secure access to valuable process data and makes it available to other production and management systems, database archives, and remote clients.

Once he started configuring the DataHub, Mr. Munoz soon realized how it could solve his data flow problem. Acting as an OPC client to TOP Server, the DataHub can request data based on tag value changes (referred to as “asynchronous advise”). This means that instead of 30,000 tags per second, TOP Server only sends data for a tag when it changes value. It is free to poll the devices in the most efficient way, always keeping the DataHub up to date with the latest data values. The DataHub keeps all the latest tag values in memory, and can efficiently send them to the HMI on each poll.

“The DataHub effectively decouples the OPC server from the client,” said Mr. Munoz. “All the load is on the DataHub’s shoulders now, and the performance is much better.” The TOP Server is now free to optimize the communications to the device while the DataHub protects it from device reads. This has relieved the company from having to redesign their HMI and PLC configurations from the ground up, saving them tens of thousands of dollars in engineering and development work.

When he was satisfied with the results at the first location, Mr. Munoz began installing the DataHub at the seven other facilities. He experienced a similar performance boost, and at the same time created a new data integration opportunity. He now had most of the pieces in place to bring all of the live production data to a central location, using OPC tunnelling.

OPC tunnelling

OPC tunnelling is a reliable and secure way to connect OPC servers and clients over a network. OPC DA uses DCOM for networking, which is difficult to configure, does not respond well to network breaks, and can pose significant security risks. The DataHub mirrors data from OPC servers and clients over TCP, which is a more robust protocol for networking.

To implement OPC tunnelling, Mr. Munoz installed another DataHub on a Windows server at the Mukhaizna oil field central office. After configuring tunnelling connections between that DataHub and the remote DataHubs, he was able to access the data from all eight field locations as a single, common data set, without putting any more load on his control system. This data could now be logged and shared at the management level of the company.

Using the DataHub’s database interface, Mr. Munoz configured connections to OSIsoft PI and SQL Server databases, to record production data at the remote sites and at the central office. Historical records and reports are now available through standard tools such as SQL and Crystal Reports. Mr. Munoz also configured an OPC connection from the central DataHub to an Iconics Web HMI to give managers access to the live data from all of the eight field sites. Operators, on the other hand, continue to control the processes from the HMIs running at the remote locations.

Among the critical information that operators and management need to monitor is the available memory and status of programs running at each field location. The company was able to achieve this by configuring the DataHub’s System Monitor feature, which allowed Mr. Munoz to add points that monitor the available computer memory and status of the OPC server running at each remote location. This data is accessed locally by operators, and is also tunnelled back to the central DataHub, so it can be viewed by users of the Web HMI on the management network.

“The DataHub is very easy to use,” said Mr. Munoz. “In fact, at a recent training session we showed some other people at the company what we are doing, and they are very impressed.”

Redundancy

The most recent project that Mr. Munoz has decided to tackle with the DataHub is to implement redundancy. To provide increased availability, the company has installed an additional OPC server at some locations. Working with Win Worrall, Product Support Engineer and Developer at Software Toolbox, Mr. Munoz has implemented redundancy in the DataHub to monitor the quality of the data coming from the local OPC server.

If the quality of an indicator changes to “Bad” or “Not Connected” on the primary OPC server, DataHub immediately switches to the redundant OPC server and continues collecting data from there. Although this is currently undergoing testing before being implemented in the production facility, Mr. Munoz reports that there is no data loss during the switchover, and that the performance is very reliable.

Scripting

To gain maximum value from the DataHub, Mr. Munoz has developed a working knowledge of the DataHub Scripting feature. “The scripting language did take a little time to learn, but it is very useful for the types of scripts we need to use. We can develop scripts quickly now, because the language is object oriented.”

Starting with a demo script from the DataHub archive, Mr. Munoz has been able to access data from a legacy UNIX system and make it available through OPC. To access the data, Mr. Munoz wrote a DataHub script to read a CSV file every minute and write the values to points in the DataHub. Because the DataHub is also an OPC server, this allows points from the UNIX system to be presented as OPC tags to the HMI system.

“I am impressed with how quickly Juan has picked up the scripting,” said Mr. Worrall. “In fact, he’s pretty good at getting the most out of the DataHub in just about every way.” “We are very grateful to Win and the overall support from Software Toolbox on this project,” said Mr. Munoz. “We haven’t found many problems. In all aspects, the DataHub is performing very well.”

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Software Toolbox and TOP Server are trademarks of Software Toolbox, Inc. Other product names, brand names and company names mentioned in this publication may be trademarks of their respective owners.

Redundancy for OPC

Early one morning, Mel Farnsworth was sitting in the control booth at the Hardy Automotive Parts assembly line, drinking his final cup of coffee before the end of the shift. Watching the line meter graph in his HMI console, he noticed that the yield and efficiency trends for the Line 3 had dropped to zero. So he looked down through the control-room window, but Line 3 seemed to be rolling right along. What was the problem?

The line was running smoothly, but Mel wasn’t getting the data he needed. Somewhere between the PLCs and his HMI display there was a data disconnect. Maybe it was a fieldbus problem, or a bad network connection. Perhaps it was caused by his OPC server, or possibly even his HMI system itself. Whatever the reason, since Mel’s data connection was a single chain, one break in the chain means that he didn’t get his data. To minimize this kind of risk and ensure the highest possible availability, mission-critical systems often use redundancy.

What is Redundancy?

Redundancy in a process control system means that some or all of the system is duplicated, or redundant. The goal is to eliminate, as much as possible, any single point of failure. When a piece of equipment or a communication link goes down, a similar or identical component is ready to take over. There are three types of redundant systems, categorized by how quickly a replacement (or standby) can be brought online. These are cold standby, warm standby, and hot standby.

Cold standby implies that there will be a significant time delay in getting the replacement system up and running. The hardware and software are available, but may have to be booted up and loaded with the appropriate data. Picture the olden days of steam locomotives. The cold standby was the extra engine in the roundhouse that had to be fired up and brought into service.   Cold standby is not usually used for control systems unless the data changes very infrequently.

Warm standby has a faster response time, because the backup (redundant) system is always running, and regularly updated with a recent copy of the data set. When a failure occurs on the primary system, the redundant system can disconnect from the failed system and connect instead to the backup system. This allows the system to recover fairly quickly (within seconds, usually), and continue the work. Some data will be lost during this disconnect/reconnect cycle, but warm standby can be an acceptable solution where some data loss can be tolerated.

Hot standby means that both the primary and secondary data systems run simultaneously, and both are providing identical data streams to the downstream client. The underlying physical system is the same, but the two data systems use separate hardware to ensure that there is no single point of failure. When the primary system fails, the switchover to the secondary system is intended to be completely seamless, or “bumpless”, with no data loss. Hot standby is the best choice for systems that cannot tolerate the data loss of a cold or warm standby system.

A Typical Redundant OPC System

What does redundancy look like in an OPC-based system? A typical scenario would have two OPC servers connected either to a single device or PLC, or possibly duplicate devices or PLCs. Those two OPC servers would then connect to some kind of OPC redundancy management software which, in turn, offers a single connection to the OPC client, such as an HMI. The redundancy manager is responsible for switching to the secondary OPC server when any problem arises with the data coming from the primary OPC server. This scenario creates a redundant data stream from the physical system all the way to the HMI.

The most common use of redundancy for OPC is with OPC DA or UA, but it is possible to configure redundant OPC A&E systems as well. The principles are the same.  Sometimes, on large systems, it is necessary to configure multiple redundant pairs. Redundancy can also be configured over a network, using DCOM or OPC tunneling. For a networked configuration, the redundancy manager would normally reside on the OPC client machine, to minimize the number of potential points of failure.

Although cold or warm standby may be useful under some circumstances, typically an engineer or system integrator implementing a redundant OPC system is looking for hot standby. This is the most useful kind of redundancy in a process control system, and at the same time the most difficult to achieve. Let’s look a little more closely at that all-important task of the OPC redundancy manager in a hot-standby system—making the switch.

Making the Switch

Put simply, a hot-standby redundancy manager receives data from two identical inputs, and sends a single output to the OPC client. It is the redundancy manager’s job to determine at all times which of the two data streams is the best, and switch from one to the other as soon as possible whenever the status changes. The switch can be triggered by a number of different kinds of events:

  • Single point value change – to or from a certain value, achieving a threshold, etc.
  • Single point quality change – for example, from “Good” to any other OPC quality.
  • Multiple item monitoring – if the quality or value of any point in a group goes bad.
  • Rate of change monitoring – if points change value more slowly than expected.
  • Network breaks and timeouts – checked with some kind of heartbeat mechanism.

Once the switch has occurred, the system or the redundancy manager itself might have the ability to send an alarm or email message, or even launch some kind of diagnostic or investigative program. It might also be able to log diagnostic information about the state of the primary OPC server or network connection. And in a system that distinguishes between primary and secondary inputs, there will often be a means to favor the primary input, and switch back to it when possible, sometimes referred to as a fallback.

Practical Considerations

The idea of redundancy for OPC is not difficult to grasp, but implementing it takes some thought. An initial decision on cold, warm or hot standby will impact all aspects of the implementation. The choice of proper hardware and software is critical for a well-functioning system. Robust system architecture is also important, especially if the connection is across a network. In addition to selecting OPC servers and planning the network infrastructure (if necessary), an important decision will be the software used to manage the redundancy. Good redundancy management software should be easy to use, with no programming necessary. The technology should be up to date, capable of running on the latest version of Windows. There should be an absolute minimum chance of data loss during a switchover, even over a network.

The Timer Pitfall

In practice it is not possible to achieve a completely seamless switchover in all cases, even with a hot standby system. For example, if a network failure occurs on the primary connection, a certain amount of time will pass before a redundancy manager can detect that failure. Data transmitted during this period will fail to arrive, but the redundancy manager will not be able to distinguish between a failure and a normal pause in data flow.

Many redundancy managers implement timers to periodically check the network connection status to try to minimize this delay, but a switchover mechanism based on periodic timers will always suffer from data loss. Systems with multiple timing parameters will often result in additive delays, where the fastest possible switchover for the system is the sum of these timing delays. In addition, the use of timers to detect network failure can result in a configuration problem where the system integrator must trade off switchover latency against false-positive network failure detection. This effectively becomes a trade off between system stability and responsiveness.

Using timers to periodically check data values or qualities, or poll the OPC servers, is also problematic because timers introduce unnecessary latency into the system. Whereas a network failure must be detected based on timing, a data value or quality change can be detected immediately as the event occurs. Generally it is usually best to avoid systems based on time-based value change detection, and use event-based object monitoring instead.

Object and Link Monitoring

A good redundancy manager should be able to support both object monitoring and link monitoring. Object monitoring means the ability to monitor individual points, and make a switchover based on an event. For example, if a designated watchdog tag changes in a significant way, such as turning negative or going over a specified threshold, it can trigger a switch to the secondary OPC server. Or maybe you’d like to monitor a group of points, and if the quality of any of them goes to “Bad” or “Unconnected”, you can switch.

Link monitoring is especially useful for networked connections. Your system will need a way to detect a network break very quickly, to prevent data loss. For hot standby on high-speed systems with fast data update rates, timeout detection with a sub-second response rate is essential. In any event, the system should be able to detect a timeout for a failed network connection, as well as a failure to receive data. This distinction is important. It may take seconds or even minutes to detect a communication failure, but a redundancy manager should be able to detect a stoppage of data flow in an amount of time very close to the true data rate from the physical system. The redundancy manager should be able to switch from one source to the other based solely on an observation that data has not arrived from the primary connection, but has arrived from the backup system.

Some systems use COM timeouts for link monitoring. This may be acceptable for circumstances where relatively long data outages are tolerable, but we do not recommend relying on COM timeouts for hot or warm standby.

Smart Switchover

The behavior of the redundancy system during a switchover can be significant. For example, suppose the primary and secondary connections have both failed for some reason. A typical redundancy manager will begin a cycle of attempting to attach to one and then the other OPC server until one of them responds. The redundancy manager will flip-flop between the two indefinitely, injecting sleep periods between each flip-flop to reduce system resource load. This sleep period is itself a source of latency. A smarter switchover model is to maintain a source health status that allows the redundancy manager to only switch over when a source status changes. This allows the redundancy manager to effectively idle, or perform simultaneous reconnection attempts, until a source status changes, then immediately respond without introducing extra latency. Smarter switching logic can result in substantially reduced system load and switchover times.

Forced Switching vs Preferred Source

It is useful to be able to select one data source over another, even if the currently attached source is healthy. A naïve redundancy manager will “force” the user to switch, even if the backup system is not available. This will again result in a flip-flop behavior as the redundancy manager attempts to switch to the unavailable backup source. A much better approach is for the redundancy manager to understand the concept of a preferred source that can be changed at runtime. If the preferred source is available, the redundancy manager will switch to it. If the user wants to switch from one source to another, he simply changes the preferred source. If that source is available, the switch will be made. If it is not, the redundancy manager will make the switch only when it becomes available. This eliminates the flip-flop behavior while at the same time eliminating the data loss associated with the minimum of two switch cycles that the naïve redundancy manager will impose.

Accessing Raw Data

A good hot redundancy system will give the client application access not just to the redundant data, but also to the raw data from both sources. This gives the client application the option of presenting diagnostic information about the system on the “far side” of the redundancy manager. Most redundancy managers hide this information so that a client application would have to make and manage multiple connections to access the raw data, if it is possible at all.

Other options and features

In addition to the above capabilities, a good redundancy manager may offer additional features for your convenience. It might provide the option to refresh the entire data set at switchover. Maybe it will send out emails or even launch additional programs at each switchover. This can be useful for notifying key personnel of the system status. It may log diagnostics to provide valuable information about the reasons for making the switch. Some redundancy managers can connect to multiple servers, and create multiple redundant connections. Others can let you work with subsets of the data. Another desirable feature is the ability to assign the primary and secondary data sources, and to trigger a fallback from the secondary to the primary data source once the problem that caused the switchover has been resolved.

As control systems continue to grow in complexity, and as we rely more and more on them, Mel Farnsworth’s situation will become more common, and more costly. If data connectivity is crucial to the success of the company, it would be wise to consider the possibility of installing a redundant system, and to take into account the above considerations when implementing redundancy for OPC.