Power Generator Switching for Power Engineers Inc. with. Distrix Software Defined Infrastructure. A Distrix Networks Case Study.

Transcription

1 Power Generator Switching for Power Engineers Inc. with Distrix Software Defined Infrastructure A Distrix Networks Case Study November, Distrix Networks Ltd. All Right Reserved 1

2 The project outlined in this case study commenced full operation in January Its objective was to increase the reliability of a serial network, and to provide dynamic reconfiguration. The Situation An islanded facility was powered by multiple micro-grids from more than a dozen diesel generators. Each grid supported varying loads with differing priorities. In order to support the facility in a cost effective manner, the generators had been configured in a way that allowed each generator to supply power to any micro-grid as load requirements demanded and to provide dynamic network reconfiguration. Generators supplying the same grid were required to maintain phase and load balance with each other. Motor controllers on each generator maintained generator speeds and outputs using information shared from the other generator controllers on the micro-gird across a twisted pair serial network carrying LonWorks. As tie breakers on the grid were tripped to modify the generator / grid configuration, the LonWorks serial network needed to be simultaneously reconfigured to re-form serial networks of the same generator configurations. As an initial attempt to provide dynamic reconfiguration of the serial networks, physical relays were installed throughout the twisted pair infrastructure that switched the connections from one physical wire connection to another. The relays were controlled by PLCs and a complex set of programs that interfaced the grid configuration with the network configuration. This solution proved unreliable and costly. Relays failed to trip due to corrosion, and outages due to cable failures were commonplace. Generation reliability needed to be increased as this system supported both Mission Critical and Life-Safety systems Distrix Networks Ltd. All Right Reserved

3 The Distrix Solution The Distrix Software Defined Infrastructure enabled the abstraction of the physical infrastructure from the data plane. Encapsulating the LonWorks serial protocol in a Distrix message structure made use of alternate infrastructure technologies for improved performance and reliability, even under challenging conditions. A complete physically redundant Ethernet network had been installed throughout the facility, and Distrix was installed on redundant physical industrial computing appliances at each generator. Each pair of Distrix Gateways (primary and secondary) connected to the single LonWorks serial connection of the generator controller. The LonWorks data was encapsulated by both Distrix gateways with the primary gateway sending the Distrix message out onto the Ethernet network as a UDP packet. Within the Distrix Software Defined Infrastructure, the role of the secondary Distrix Gateway is to ensure the packet is sent by the primary and in the case of a serial connection failure at the primary, or a failure of the primary gateway, the secondary gateway transmits packets and assumes primary communication duties. In this case the generator in question was effectively protected from communication faults. In this setup Distrix provided the highest levels of redundancy across the network by sharing the UDP packet with all Distrix Gateways on the Ethernet network while the proprietary Distrix Routing Layer intelligently directed packets through that network using the path of least resistance to the gateways connected to generators supporting the same grid. The packets were then un-encapsulated and handed off back to the LonWorks Serial bus connected to the generator controller. As such, Distrix Software Defined Tunnels effectively enabled the dynamic reconfiguration of the LonWorks endpoints. The Distrix Endpoints, which may be point to point or point to multi-point, were defined by the Distrix Policy Engine. In this case a custom policy was used to interface with Modbus registers on the PLC controlling the Grid tie breakers. 3

4 The Distrix Solution Figure 1 Simplified Schematic of the Infrastructure (redundancy not shown) Distrix Networks Ltd. All Right Reserved

5 The Distrix Result Distrix provided the Software Defined Infrastructure capabilities to create a dynamically segmented serial network with redundancy capabilities for a highly available network that provided upwards of 5 9 s ( %) reliability. Distrix provided the confidence needed by engineering and support teams to provide power to the critical systems they were responsible for. Single points of failure in the system were reduced to the generator motor controllers at the edge. Serial connections were given a layer of redundancy, and a minimum of 4 parallel hardware failures would need to occur to cause a failure in the Ethernet network between generators. The system has now been in production since January 2014, and despite at least two known hardware failures during operation, no communication outages have been experienced since deployment. The panel for a generator showing the redundant components during the Factory Acceptance Test. 5

6 About Distrix Embedding Intelligence into Complex Networks Distrix unlocks the benefits of advanced, integrated enterprise and operational systems to increase security, competitiveness and asset utilization while reducing initial and ongoing costs and risks. Distrix provides a secure, resilient and versatile Software Defined Infrastructure which interfaces with operational networks and overlays existing information networks, dramatically reducing the effort and cost of deployment and integration through its simple ease-of-use and ability to retain infrastructure investments already in place. With a remarkably small footprint, Distrix Networks centralize analysis where appropriate, and embeds logic and control at the edge when needed. Distrix currently delivers the enabling technology to give government and industrial enterprises a head start in the Industrial Internet revolution. To contact our offices: Distrix Networks Ltd West 1st Ave, Suite 200 Vancouver, BC V6J 1G5 Canada info@distrix.com Distrix Networks Ltd. All Right Reserved