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Download: Sibur-Tumen Uses OPC Redundancy in Critical Plant Application

"With Matrikon’s OPC Redundancy Broker, there has been no system downtime and no data loss."
Yuri Simakov
Chief of Industrial Automation Department, Sterling Group

Staff at Sibur-Tumen’s gas processing plant in western Siberia needed to integrate a process control system for their compressor station. To implement the project, Sibur-Tumen retained Sterling Group, a leading Russian integrator. In addition to providing a reliable, continuous connection, the required solution would have to connect 7,000 points.

After exhaustive research, Yuri Simakov of Sterling Group chose Matrikon OPC to integrate the project.

The gas processing plant was using the fault-tolerant Triconex Tricon V9 because it offers triple redundancy and is industrially ruggedized to withstand the extreme weather conditions experienced in Siberia. The system uses two-out-of-three voting to provide high integrity, error-free, uninterrupted process operation with no single point of failure. The Tricon controller would connect to two SCADA workstations running the Rockwell View32 OPC client application. RSView32 is an integrated, component-based HMI for monitoring and controlling automation machines and processes.

The Tricon control system provided redundancy at the device level, but server level redundancy was also important. To ensure reliability, redundant Matrikon OPC Servers for Triconex Tricon were installed on two separate computers. To handle the fail-over from the primary OPC server to the standby OPC server, Matrikon’s OPC Redundancy Broker (ORB) was installed on a third computer. ORB constantly monitors the primary OPC server. When a failure is detected it automatically redirects communication to the standby OPC server.

The OPC integration provided the connectivity needed to read and write data between the Tricon and RSView32 HMI.

"For this integration, it was critical that the servers operate continuously 24 hours a day, 365 days a year," Simakov says. "We were using the in-built capabilities of the SCADA system to switch between OPC servers, but the delay during the switching caused several seconds worth of data to be lost. With Matrikon’s OPC Redundancy Broker, there has been no system downtime and no data loss."

The integration of Matrikon’s OPC Servers and OPC Redundancy Broker was a success. Because Matrikon’s OPC is plug & play technology, Sterling Group did not require third party integration services to get the project up and running, even with the large number of points that were connected. Simakov says he plans to include Matrikon OPC in the future when the system is expanded.

"After my first experience integrating OPC with Matrikon, I wouldn’t hesitate to use their products in the future," Simakov says.

Since 1992 Sterling Group, a Russian integration company, has been delivering hi-tech solutions in the field of information, automation and telecommunication technologies.

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