Optimization vs.

Performance in the
modern process control systems
Massimiliano Veronesi
Sales Support and Marketing
Process Control & Safety Systems
Vigilant Plant Services & Solutions
Yokogawa Italy OMC 2015
Ravenna

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Copyright Yokogawa Electric Corporation
<March 24, 2015>
Contents

Control Hardware Optimization by Universal I/O

Shortening the delivery through loop-check anticipation
HMI Hardware optimization through Virtualization
Others ways to optimization

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Copyright Yokogawa Electric Corporation
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Why we are here: the Industry Challenge
Increasing
Strong Regulations Supply/Demand
competition Fluctuation

Consumer
Safe &
Secure Streamlined power
Operational
Operation Production
Excellence
Maximum
Quality
Asset
Aging utilisation
Assurance
Operators

Environment Aging assets

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Copyright Yokogawa Electric Corporation
<March 24, 2015>
 Focus on the system design and project development

Plant
Lifecycle

Design Build Operate Maintain Optimize Expand Upgrade

Front End Project Unplanned Human Errors Alarm Products System

Engineering Execution Outages Flooding obsolesce upgrades

Project Execution
Managing uncertainty, project complexity, late changes, cost overruns, and
deplays. The challenges gets even greater when the lack of manpower and
technical resources are factored in.

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Versatile Hardware and Flexible
Project Execution

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 Design & development: Smart Engineering

Asset
Automation Design Suite Management
System

Integration
Yokogawa
repository Historian
(module library)

MES

A
Solution
Module Bulk Change Auto Doc Flexible Packages
engineering engineering management generation binding

Automation Design Suite goes beyond traditional DCS engineering functionality.

An integrated platform that facilitates project execution, systems integration, and site execution, delivers
certainty and confidence throughout all project phases.

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Software debugging: Virtual Test Function

Simulate complete DCS on computers

Full-scale system can be tested without target hardware
Wireless debug (wireless Factory Acceptance Test)
Snap shots for evaluations
Seamless integration with training simulation models

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 Avoiding Project Delays

Reduce delays and be assured of starting production

on schedule

Application validation during FAT Designed & constructed on site

Last minute software

marshaling
Virtual I/O wiring Smart Configurable IO
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- Electric
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<March 24, 2015>
 Hardware: Universal I/O reduces the footprint.
Traditional I/O

Marshalling
Controller IOM Junction box
board

Universal I/O

Marshalling
Controller IOM Junction Box
baord

I/O design and relative works are eliminated.

Work Work Work

*I/O list & Controller sizing *Cabinet design *JB design
*Power, grounding & fusing design *Jumpers & terminations *Jumpers & terminations
*I/O design *Wiring diagrams *Wiring diagrams
*Spares sizing *Cable layout *Cable layout
*Cabinet design
*Conduit & cable layout
*P&IDs
*Process narratives
*Installation package
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Smart Configurable I/O

Best of both World

Universal I/O + Signal Conditioner

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 Next Generation Smart I/O: N-IO (Network I/O)

N-IO is designed with fewer components. I/O backplane

A single module can be configured to
support AI/AO/DI/DO. Universal I/O module
16 I/O channels
An optional signal conditioner can be Signal: AI/AO/DI/DO
plugged in to support a wide range of I/O Software configurable
signal types. HART 7 support
Full redundancy
The backplane allows I/O redundancy by
design, resulting in a smaller footprint. Signal conditioner
(optional)
Wide range of I/O
Pulse, relay, DO, etc.

Termination block

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 IO network Configuration
System Network Vnet/IP
Node Interface Unit
Up to 100m - Lower performance
- Heavy load in the
by copper FCS system network might
affect real-time
computations
N-ESB bus
- Less secure
- System network is
connected to OWS
- Less robust
- Field environment
might be hard for std.
switches, hubs

Performance
first !
N-ESB bus
Up to 50 Km by optical fiber, 100 Mbps
Cat5e cable
No hub or switch is required
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 IO network Configuration
System Network Vnet/IP
Node Interface Unit
Up to 100m
by copper FCS

N-ESB bus

- Next step under development:

I/O bus shared among (limited
amount of) different controllers

N-ESB bus
Up to 50 Km by optical fiber, 100 Mbps
Cat5e cable
No hub or switch is required
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Termination

Analog Digital Mix

Signal Signal Signal
AI DI AI
AO DO AO
AI DI AI
AO Relay DO AO
AI DI AI
AO DI AI
AI DO Pulse
AO DO Pulse
AI DO DI
AI DO DO
AI DI DI
AI DI DO
AI Relay DO DI
AI Relay DO DI
AO Relay DO Relay DO
AO Relay DO Relay DO

Field Signal Cables

Plant
Area
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Electric
<March 24, 2015>
Marshalling Comparison of FIO and N-IO

Marshalling Traditional (cross-wiring) Marshalling N-IO

Terminals
Terminal Board

Duct Duct

Smart IO
Terminal Board

Smart IO
Field Cables Field Cables
(Multicore) (Multicore)

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 Footprint: N-IO vs. Conventional IO

Conventional

X5 X5 X7 17
Cabinets

A-IO:
2,000
System Analog Mar. Digital Mar.
D-IO: Cabinet Cabinet Cabinet

3,000

Total:
5,000
10
N-IO

X1 X9
Cabinets

System N-IO
Cabinet Cabinet
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<March 24, 2015>
N-IO for Hazardous Applications

Non-IS Intrinsic safety

N-IO IS base plate H-System IS base plate 4500 series

Yokogawa P+F MTL

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Field Loop-Check wihout the controller
HIS AD Suite Project
Database

Vnet/IP
SCS FCS FCS
Local Cabinet can ship to site w/o FCS.
ESB Bus ESB Bus

N-ESB Bus

FIO FIO N-IO Validation Tool

Local
Cabinet

Scope of New
Validation Tool (VT)

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 Comparing With Current work and Flexible Binding Workflow

Reduce the time span.

Deadline of IO freezing is shifted by flexible binding

Construction Phase
Current Workflow (CPU, Cabinet,
Transmitter)/
CPU
TEST
Connection /
indiv. Loop check
Total Loop
Check/
Commissioning
Opera-
tion
Execution FAT Shipping Wiring Work

I/O Binding
(Freeze specification) End of Execution

End of Wiring Check

YOKOGAWA Flexible Binding

Construction Phase

Construction
(Cabinet, CPU Total Loop
Connection / Opera-

CPU
Check/
Transmitter)/ indiv. Loop check Test Commissioning
tion
Wiring Work
Execution FAT Shipping

Work at site - 22 -
Work in-house
Virtualization

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Why virtualization in industrial plants now ?

To reduce the number of PC boxes in plants

It tends to increase the number
of ?? server, ?? historian, etc.
There is increasing of concern of both CAPEX and OPEX
e.g. Foot-print, OS maintenance, power consumption
The number of server PC is a serious issue
for the control systems with server-client architecture
To segregate the maintenance of hardware and software
Windows OS is migrating every a few years and the previous OS
becomes obsolete soon
The latest PC hardware and previous OS may not be compatible
Many of software applications in the control systems highly depend
on OS and are less compatible with newer OS
Maintenance concern at the failure of the existing PC hardware

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<March 24, 2015>
CAPEX Reduction - General Evaluation -
Adopting VMware for
virtualization
1:10 server consolidation ratio
(10 virtualized machines can
run in a server)*
Lower electric power
consumption and cooling cost
Reduction of maintenance cost 600
Reduction of footprint
400
Smoother component migration
Easy backup and restore 200

KUSD

* This is an assumption, it will depend on the

application for the real project

Small Medium Large

Not virtualized Virtualized Not virtualized Virtualized Not virtualized Virtualized

No. server 20 2 50 5 100 10

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OPEX Reduction - General Information -

Space, weight, and number of boxes/cabinets

Assumed that server height is 2U, and 7 servers can be installed in a cabinet
Small Medium Large

Not virtualized Virtualized Not virtualized Virtualized Not virtualized Virtualized

No. server 20 2 50 5 100 10

No. cabinet 3 1 8 1 15 2

Power consumption assumption $600,000

No matter the size of the project,
virtualization can reduce 84% of Virtualized
the power consumption than $400,000
non-virtualized system Not virtualized

Small/medium/large $200,000

Not virtualized Virtualized

USD
100% 16%

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 Types of Virtualization: Host type vs. Hypervisor type

The virtualization works as Works as the host OS

an application on the host PC resource can be
OS such as Windows, consumed as much as
Linux possible for virtual PCs
VMware Workstation, VMware ESXi, Microsoft
VirtualBox, etc Hyper-V, RedHat KVM, etc.

APP APP APP APP APP APP

Guest OS APP
Guest OS Guest OS
Virtualization S/W
Virtual PC Virtual PCs Virtualization S/W
Host OS
Hardware
Hardware

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Comparison between Host type and Hypervisor type

Host type Hypervisor type

Acceptability Easy to use Some level of
knowledge is required
Resource usage Larger overhead Smaller overhead
(Lower performance) (Higher performance)
Security Low High
Scale Small Large
Performance Low High

For server virtualization in working environment,

hypervisor tends to be adopted
Official support of Yokogawa systems are also in hypervisor type
However using Hyper-V is not recommended for workstation with
Yokogawa components inside
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The performance issue

Virtual network is working in the virtualization software

Virtual NICs and virtual switches are working (emulating)
Only Physical NIC are suitable for real-time
deterministic applications Performance first !

Virtual Network

Actual network
Virtualization S/W

Actual NIC (hardware)

Other PCs
Actual network switch

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The performance issue
If the PC is a quad core machine then 3 virtual machines may be the
maximum to be deployed (1 core for the main application and 1 core for
each of the 3 virtual PCs). If Hyper-threading is enabled, then double the
number of cores are required.
(Number of requested cores) = (CPU reservation frequency) (Frequency of
CPU of physical server) x 2 if HT is enabled
(CPU reservation frequency) = (CPU req. frequency) x (Number of cores) 2
Es.: Required CPU resources are 3.00 GHz and 4 cores, with 2.8GHz physical Server:
(CPU reservation frequency) = 3.00 GHz x 4 cores 2 = 6 GHz
(Number of req. cores) = (6/2.8) 2 = 2.14 2 = 4.28 5 (rounded up)
Condition:
[CPU reservation frequency of Yokogawa Products] x 1.25 < [CPU
resource]
Where [CPU resource] = [CPU frequency - in GHz] x [No. of cores] x [No. of CPUs]
Es. Sum of CPU reservation frequency = 6.00 + 6.00 = 12.00 GHz
the CPU resource for one server machine with frequency 2.60 GHz and 8 cores is 2.6 GHz x
8 cores = 20.8 GHz
12.0 x 1.25 (VMSphere Overhead) < 20.8
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The performance issue
Using SAS3 or RAID4 configuration to secure the performance is needed.
Using SSD5 is not recommended because of lower endurance.
VMware allows three types of formatting for virtual storages. It is strongly recommended
to adopt Thick provisioning (Eager Zeroed) with securing area in advance and with
executing zero formatting. Using Thin provisioning causes lower performance, and Lazy
Zeroed causes disk access error.
It is mandatory to configure the Yokogawa product to use enough memory
area exclusively to secure performance in both off and on-process.
Generally the clock of guest OSs may be delayed when the load on
Hypervisor becomes too high. If the demand of time synchronization is
severe, the synchronization period should be set shorter.
One physical server PC failure stops multiple server functions: highly
available industrial server is recommended

SAS (Serial Attached SCSI): The interface to connect up devices for hard disk drives to computers
RAID : Redundant Array of Independent Disks
SSD : solid-state drive using flash memory

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 Virtualization Benchmarking

Current Yokogawa
System architecture

Virtualized Architecture

Benchmarking: Number of PC (Server/Workstation)

Small Medium Large
20 50 100

Performance First: Excluding Servers with Vnet/IP modules

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Example of on-process systems

Historian Pilot APC KPI AMS

PJT ENG/HIS HIS Exaopc

database
Server

Vnet or Vnet/IP
FCS

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Example of on-process systems

Client stations

VM Server

AMS Instr.
Historian Pilot APC KPI
SOE Maint.

Win
Win 7 Win 7 Win 7 Win 7 Win 7
ENG/HIS HIS 2008
OPC
VMware

Vnet or Vnet/IP

FCS

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Example of off-process systems Operator Training systems

Trainees clients Instructors

OmegaLand FCS FCS SCS SCS HIS HIS

Win 2008 FCS FCS SCS SCS Win 7 Win 7
FCS FCS SCS SCS
ExaPilot ExaOPC FCS FCS SCS SCS ENG/SENG/HIS HIS
Win 7 Win 2008 Win 7 Win 7 Win 7 Win 7

VMWare

OTS on VM Server

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Other performance vs. optimization

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Integration with subsystems: which way ?
Sub-system communications Modbus / Profibus
Redundant Configuration is
Data for HMI: OPC/ModbusTCP available.
Client (redundant) workstation
can manage up to 100,000
variables DCS network
Data for control logics: put
(redundant) communication UGS
module in one rack of the related
CPU in charge
RTU network

OPC DA+HDA (or UA) Modbus/TCP (or RTU)

Benefits - Lower Controller CPU load - Simple reliable industrial solution
- High throughput - Subsystem data directly available in
- A&E by OPC A&E DCS controller for control/logic
functions
Drawbacks - Unreliable IT technology - Affecting Controller CPU load (to be
- Subsystem data NOT directly distributed among the DCS controllers)
available in DCS controller for - Not supporting A&E with timestamps
control/logic functions

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 Integrated Process Control & Safety System
Integrated Control+Safety system provides optimization
+ performance at the same time
Application SIS Application DCS

SIS DCS
Data Tagnames equalization Data
base base

EWS EWS
SIS DCS

V net/IP Master station automatically

assigned
Reference time broadcasted
every 10 seconds
Time shifts are adjusted very
smoothly 0.005 ms (0.05%) at
10 ms interval.
External clock synchronization
Safety Controller DCS Controller available (via time server)

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Multi-monitor vs. performance
Multi-monitor/Graphic windows
Each mimic call data from the system bus
while one single operator cannot pay
attention to more than 512 windows at the
same time: prevent it by limiting the number
of graphic windows which can be called by
the operator by FIFO mechanism.

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Others ways to optimization
Alarm optimization
Complying to ISA18.2 and Eemua-191 Standard
Control Loop Performance Monitoring
Evaluate improvements through simulations
Best Practices Employment
Operator sequences executed by flow-charts
Plant performance quantitative
measurements
KPI, Downtime analysis, Data reconciliation
Sequence of events and Safety Functions
monitoring
Energy management
Monitoring or optimization
APC
Multivariable Predictive Control

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APC: Multivariable Predictive Control

104

102 Specification or limit

100
PERCENT OF LIMIT

98
Benefits
96

94
Operator target
92 Standard deviation
SETPOINT MOVED of controlled variable
BEFORE APC APC ONLINE CLOSER TO LIMIT
90

Base Case Stabilise

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Optimization aimed solutions

Safety and
Production Asset Energy Knowledge
Security

Human
Production Asset Energy Asset Procedure
Performance Performance Performance Environment Performance
Protection

Process
Supply Chain Greenhouse
Predictive Control Knowledge
Management Environment
Maintenance Domain Retention
Performance Control
Security

Operator Do not load the DCS with these

Effectiveness
tasks: do it at upper level !

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 Wireless Transmitters: be careful with PID control

Increased plant productivity and availability

with ISA100 wireless for process control

The new CENTUM VP supports a new PID block

specialized PID function block that with packet-loss
compensates for any packet loss. With this compensation
function block, the dynamic response after
signal recovery is smooth and stable. As a
result, wireless control is dependable.

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Conclusions
Different kind of Optimization or Functions are attractive and may lead to
significant Capex/Opex reductions
but also to some performance issues.
Clever engineering should carefully consider the right balance between
optimization and performance with respect to the specific application

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Thank you for your
attention!

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Any question ?

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