Process Control System Hardware Virtualization
Find Innovative SolutionsGenerate Solutions
Solution Overview
Problem
Conventional process control systems in industrial plants have a shorter lifespan than the plants themselves, necessitating frequent replacements, which are costly and disruptive, as they rely on general-purpose electronic components that limit the system's longevity.
Innovation Solution
The implementation of a process control system that uses a hypervisor running in hardware to enable the replacement of hardware components without altering the existing operating system and applications, allowing for flexible upgrades and additions while maintaining compatibility, and incorporating redundant controllers for increased reliability and minimal downtime.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Ease of manufacture
If general-purpose electronic components are used in controllers, then the system can be manufactured with standard components, but the system lifespan is limited to approximately 10 years
Solution Approach 1:
The system is segmented into hardware components and software components (operating system and applications). The hardware can be replaced independently while the software remains unchanged, allowing the system lifespan to extend beyond the hardware lifecycle without requiring complete system replacement.
Solution Approach 2:
The controller hardware is designed with universal interfaces and standardized communication protocols that allow different hardware generations to work with the same operating system and applications. This enables seamless hardware upgrades without software modification.
2Duration of action of stationary object
If the process control system is replaced to extend its lifespan, then the system can continue operating, but the plant must stop for a long period causing lost revenue
Solution Approach 1:
Redundant controllers are prepared in advance and kept in standby mode. When hardware replacement is needed, the standby controller immediately takes over, allowing the replacement to occur without interrupting plant operations. This eliminates downtime and associated revenue loss.
Solution Approach 2:
A hypervisor layer is introduced as an intermediary between the hardware and the operating system. This allows hardware changes to occur at the physical level while the hypervisor maintains continuous operation, preventing any interruption to the control system and eliminating downtime.
3Ease of manufacture
If I/O cards with general-purpose electronic components are used, then the controller can be manufactured with standard components, but the controller lifespan is limited to approximately 10 years
Solution Approach 1:
The functionality of physical I/O cards is copied into software form within the operating system. This virtualization allows the same I/O functionality to be maintained across different hardware generations without requiring physical card replacements, effectively extending controller lifespan while maintaining ease of manufacture through standard hardware platforms.
4Adaptability or versatility
If new technology is adopted, then the system can benefit from technological advances, but the existing process control system must be completely replaced
Solution Approach 1:
The system architecture is made dynamic by separating hardware from software and introducing virtualization layers. This allows the hardware to be updated to incorporate new technology while the software layer remains stable, enabling technological adaptability without complete system replacement and reducing replacement complexity.
Data Source
Figure 1
Figure 2
Figure 3
AI summary
A process control system (1) performing control of an industrial process implemented in a plant, may include: a network (N) provided in the plant; a plurality of field devices (11, 12) connected to the network, each of the plurality of field devices is configured to perform at least one of measurement and actuation required for control of the industrial process; and a controller (20), connected to the network, having a virtual part (22) and a control unit (23, 24)configured to operate in the virtual part and to control operations of the field devices via the network, the controller being configured to enable replacement of hardware without changing the control unit.