Contents

PREFACE xi

Chapter 1 INTRODUCTION AND OVERVIEW 1

Automation Software, 2
Software Hierarchy, 32
History of Automation Software, 35
Evolution of Software Architecture, 37
Exercises, 40
References and Bibliography, 41

Chapter 2 BENEFITS, SAVINGS & DOUBTS 43

Realizing Benefits from Software Connectivity, 43
Reducing Capital Expenditure (CAPEX), 54
Reducing Operational Expenditure (OPEX), 57
Software Concerns Addressed, 61
Exercises, 65
References and Bibliography, 65

Chapter 3 SETUP 67
Application Execution, 67
System Networking, 69
DCOM Setup, 74
Windows XP Software Firewall, 87
License, 88
Exercises, 95
References and Bibliography, 95

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Chapter 4 CONFIGURATION AND SCRIPTING 97

Live Data Interface (OPC-DA and DDE), 97
Historical Database Interface (OPC-HDA), 126
Live Alarm & Event (OPC-A&E), 133
Reporting and Analysis (OLE_DB), 148
Scripting (VBA), 152
Components and Controls (ActiveX), 153
OPC Marshalling, 154
Other Functionality, 160
Exercises, 160
References and Bibliography, 161

Chapter 5 ENTERPRISE INTEGRATION & SYSTEM MIGRATION 163

Web Visualization, 165
Enterprise Integration, 171
Automation System Coexistence & Migration, 180
Exercises, 182
References and Bibliography, 182

Chapter 6 TROUBLESHOOTING 183

DCOM Troubleshooting, 183
OPC Troubleshooting, 186
NetDDE, 194
DLL Hell, 194
Memory Leak, 195
License Restrictions, 195
ActiveX Registry Issues, 195
Exercises, 195
References and Bibliography, 196

Chapter 7 APPLICATION 197

Automation Level Software, 197
Data Servers, 212
Industrial Computer Peripherals, 214
References and Bibliography, 220

Chapter 8 ENGINEERING & DESIGN 221

Design, 221
Test, 227
Documentation, 227
Exercises, 232
References and Bibliography, 232
 Table of Contents ix

Chapter 9 MANAGEMENT & ADMINSTRATION 233

Backup & Restore, 233
Monitoring & Performance Tuning, 235
Database Maintenance & Repair, 238
Upgrade & Change, 239
Exercises, 240
References and Bibliography, 240

Chapter 10 SAFETY, AVAILABILITY & SECURITY 241

Safety Integrity, 242
Availability, 246
Cyber Security, 255
21CFR11 Electronic Records and Electronic Signatures, 292
Exercises, 298
References and Bibliography, 299

Appendix A ACRONYMS 301

Appendix B SOLUTIONS TO EXERCISES 307

Appendix C ATTRIBUTES OF OPC ITEMS 313

INDEX 319