Download Power Generator Switching for Power Engineers Inc. Distrix

Power Generator
Switching for
Power Engineers Inc.
with
Distrix Software
Defined Infrastructure
A Distrix Networks Case Study
November, 2015
© 2015 Distrix Networks Ltd. All Right Reserved 1
The project outlined in this case study commenced
full operation in January 2014. 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.
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© 2015 Distrix Networks Ltd. All Right Reserved
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.
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The Distrix Solution
Figure 1 – Simplified Schematic of the Infrastructure (redundancy not shown)
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© 2015 Distrix Networks Ltd. All Right Reserved
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 (99.99999%) 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.
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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.
1880 West 1st Ave, Suite 200
Vancouver, BC V6J 1G5
Canada
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1-855-657-7275
[email protected]
http://www.Distrix.com
© 2015 Distrix Networks Ltd. All Right Reserved