Design of the Ethernet based process data extraction algorithm and storage technique for industrial HMI systems

Due to control and monitoring of large number of process signals in a 365/24/7 process plant, any HMI (Human Machine Interface) application has its limitation for persistent long-term storage of the process data and effective analysis. The data in Siemens HMI application WinCC (Windows Control Centre) and many other applications is in compressed and encrypted form and cannot be accessed using standard SQL Queries. In this paper, high-performance data extraction algorithm of encrypted process data and its subsequent storage technique over the network in real time from redundant HMI (WinCC Servers) is proposed. The results of better response rates and minimum resource utilization are achieved for the proposed algorithm and storage technique in comparison to the existing softwares available for this purpose. The system developed on the proposed algorithm and storage technique is deployed and in operation at various Cement Plants and Water Pumping Stations for more than two years.