OPC based distributed real time simulation of complex continuous processes

This paper presents a methodology for the development of distributed process simulation using OPC (OLE for Process Control). The distributed components operate as OPC servers enclosing continuous simulations developed with the simulation language EcosimPro. The paper presents the problems related to data interchange and synchronisation in real time and the solutions adopted and gives results about the performance of OPC in this kind of applications. The methodology has been applied to a large process simulator of a beet sugar factory used for control room operator training. This includes a process simulation operating in a network of six computers, a SCADA system for operation on the process, an instructor console and the corresponding software for real time communication and synchronisation. The main advantages of this approach are: (i) independence of the development of the simulation from the communication mechanisms, (ii) access to the simulations by a wide range of applications, due to the standard provided by OPC, (iii) use of low cost conventional equipment and (iv) support for large scale simulations.