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DeltaV-Backend Integration

Industrial Process Integration Platform Production

🏭 Project Overview

A mission-critical industrial integration platform bridging Emerson DeltaV control systems with backend databases for petroleum terminal operations. This production system handles real-time bidirectional data flow for truck loading operations, badge authentication, recipe management, and tank monitoring. Operating continuously for 15+ years at a major petroleum terminal with zero unplanned downtime.

  • Real-Time Integration - Bidirectional data exchange between DeltaV and backend databases via OPC DA
  • Badge Authentication - CSN (Card Serial Number) validation and conversion for driver identification
  • Recipe Management - Automated synchronization of product recipes and blending parameters
  • Loading Operations - Complete truck loading lifecycle management across 8 loading stations
  • Tank Monitoring - Real-time tank inventory and connection status tracking
  • Offline Resilience - Automatic offline badge creation when backend systems are unavailable
  • Watchdog Monitoring - Self-healing workflow recovery for maximum uptime
  • 15+ Years Proven - Continuous operation in a 24/7 industrial environment

🎯 Key Features

  • 🔗
    OPC DA Protocol Implementation - Full OPC DA client for real-time tag reading and writing to DeltaV control system
  • 🪪
    Badge Authentication Flow - Multi-step validation: CSN scan → Badge ID conversion → Order lookup → Loading authorization
  • 🔄
    Workflow Engine - Event-driven workflow orchestration for complex loading sequences
  • 📊
    Recipe Synchronization - Automatic sync of product recipes, tank configurations, and blending percentages from backend
  • 🚛
    Loading Station Management - Real-time status tracking for 8 simultaneous loading bays
  • ⚠️
    Offline Mode - Graceful degradation with offline badge creation when backend is unavailable
  • 🔐
    Linked Server Integration - Secure SQL Server linked server connections to backend database
  • 💓
    Watchdog & Self-Healing - Automatic detection and recovery from blocked workflows

🏗️ Architecture & Technology

Technology Stack

Industrial Protocols

OPC DA DeltaV Real-Time Event-Driven

.NET Framework

C#/.NET Workflow Engine Windows Service SQL Server

Data Layer

Linked Servers Stored Procedures Transactions Audit Logging

Deployment

On-Premises DeltaV Station 24/7 Operations Industrial Network

System Architecture

The integration platform operates as a Windows Service on the DeltaV Application Station, acting as a bridge between:

  • DeltaV Control System - Emerson DeltaV via OPC DA for tag reading/writing
  • Local Database - SQL Server for transaction management and caching
  • Backend Database - Enterprise backend via SQL Linked Server for orders and recipes

Data Flow Categories

  • LOP (Loading Operations) - Badge validation, order lookup, loading control parameters
  • SFC (Shop Floor Control) - Loading station status, real-time progress updates
  • TNK (Tank Operations) - Tank inventory, connection status, density values
  • Recipe Management - Product recipes, blending percentages, tank mappings

🔄 Badge Authentication Flow

Complete Badge-to-Loading Sequence

The badge authentication process involves multiple systems working together in real-time:

  1. Badge Scan - Driver scans badge at loading station → DeltaV reads CSN (hex)
  2. CSN Conversion - Interface converts CSN to Badge ID via backend lookup
  3. Order Validation - Backend validates badge and returns order details
  4. Local Transaction - Create loading transaction with unique ID
  5. Recipe Loading - Write product recipe and tank parameters to DeltaV
  6. Loading Process - Monitor progress, update quantities in real-time
  7. Completion - Report final quantities to backend, archive transaction

Status Handling

  • Normal Flow - Badge validated, loading proceeds automatically
  • Already Loaded - Badge rejected if already used
  • Wrong Station - Badge assigned to different loading bay
  • No Recipe - Product not configured for loading
  • Interrupted - Loading can be resumed with same badge
  • Offline Mode - Operator creates manual badge when backend unavailable

A few Samples of Operational Workflows

🛡️ Reliability & Resilience

High Availability Features

  • Watchdog Monitoring - DeltaV RAMP counter detects blocked workflows
  • Auto-Recovery - Automatic workflow restart when blockage detected
  • Offline Badge Creation - Operations continue when backend unavailable
  • Linked Server Retry - Exponential backoff on connection failures
  • Transaction Logging - Complete audit trail of all operations

Operational Statistics

  • 15+ Years - Continuous production operation
  • 8 Loading Stations - Simultaneous multi-bay support
  • 24/7 Operations - Unattended overnight loading capability
  • Zero Data Loss - All transactions persisted and auditable

📡 Integration Points

DeltaV OPC Tags

The interface manages hundreds of OPC tags across multiple categories:

  • Badge Tags - DV_BADGE_CODE, MIS_BADGE_ID, BADGE_STATUS
  • Loading Tags - PRODUCT, ORDER_NUMBER, MT_ASKED, MT_DELIVERED
  • Recipe Tags - TANK_1..4, PERCENTAGE_1..4, DENSITY values
  • Status Tags - LS_STATUS, LOAD_START, LOAD_STOP, ERROR_MSG
  • Watchdog - RAMP counter for health monitoring

Backend Stored Procedures

  • Badge Operations - Badge_Convert_CSN, Badge_Read_New, Badge_Loaded_New
  • Recipe Sync - GetRecipes, GetRecipe_Parameters, CheckRecipesStatus
  • Status Updates - Loading_Stations_Status, Tank_Prod_Densities

🎓 What This Project Demonstrates

DeltaV-Backend Integration showcases expertise in:

  • ✅ Industrial Protocol Implementation - OPC DA integration with Emerson DeltaV
  • ✅ Real-Time Systems - Sub-second response times for industrial control
  • ✅ Mission-Critical Reliability - 15+ years of continuous operation
  • ✅ Complex Workflow Orchestration - Multi-step loading sequences
  • ✅ Database Integration - SQL Server linked servers, transactions, stored procedures
  • ✅ Resilience Patterns - Offline mode, watchdog monitoring, auto-recovery
  • ✅ Industrial Domain Knowledge - Petroleum terminal operations, loading logistics
  • ✅ Long-Term Maintenance - Supporting and evolving production software over decades

📋 Project Status

DeltaV-Backend Integration is a production-deployed solution that has been running continuously for over 15 years at a major petroleum terminal. The system handles critical loading operations 24/7 and has proven its reliability through multiple DeltaV upgrades and backend migrations.

  • ✅ 15+ years continuous production operation
  • ✅ Multiple major upgrades completed successfully
  • ✅ 8 loading stations supported simultaneously
  • ✅ Ongoing maintenance and enhancement
  • ✅ Modernization roadmap in development

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Industry: Petroleum Terminal Operations - Industrial Process Integration