Apparatus and method for guaranteed batch event delivery in a process control system

An apparatus comprising:

• at least one memory configured to store a unique identifier associated with a first event received from a controller, the first event associated with execution of a recipe control module by the controller in an industrial process control system that is associated with production or processing of a product, the recipe control module defining at least one production or processing requirement for a batch of the product and having a set of phases, each phase associated with a sequential control module, each sequential control module configured to implement the associated phase of the recipe control module;
• and
• at least one processor configured to:
• receive a second event from the controller through a control data access server, the control data access server configured to provide secure data access to and from a control execution environment of the controller;
• determine whether any events between the first event and the second event have not been received from the controller using the unique identifier;
• initiate an event recovery if at least one event between the first event and the second event has not been received from the controller;
• and
• communicate a request for the event recovery to the controller through the control data access server;
• wherein the control data access server is configured to deliver the events to a notification client for storage in a notification queue, and a notification manager is configured to retrieve the events from the notification queue and to store the events in an event list;
• wherein an event system data component is configured to determine if any of the events are missing using unique identifiers associated with the events from the event list;
• wherein the controller is configured to recover at least one event from a buffer of the controller in which the events are stored in response to the request and to communicate the at least one recovered event to the control data access server for delivery to the supervisory device;
• and
• wherein the controller is configured to prevent deletion of the recipe control module until all events generated by the recipe control module have been journaled.

A non-transitory computer readable medium embodying a computer program, the computer program comprising:

• computer readable program code for generating multiple events associated with execution of a recipe control module by a controller in an industrial process control system that is associated with production or processing of a product, the recipe control module defining production or processing requirements for a batch of the product and having a set of phases, each phase associated with a sequential control module, each sequential control module configured to implement the associated phase of the recipe control module, each event associated with a unique identifier;
• computer readable program code for storing the events in a buffer of a memory in the controller;
• computer readable program code for communicating the events from the buffer to a control data access server for delivery to a supervisory device associated with the controller, the control data access server configured to provide secure data access to and from a control execution environment of the controller;
• computer readable program code for delivering, by the control data access server, the events to a notification client for storage in a notification queue;
• computer readable program code for retrieving, by a notification manager, the events from the notification queue and storing the events in an event list;
• computer readable program code for determining, by an event system data component, if one or more events are missing using the unique identifiers associated with the events from the event list;
• computer readable program code for receiving, by the controller, a request from the control data access server to recover one or more of the events for the supervisory device in response to determining that at least one event is missing;
• computer readable program code for recovering at least one of the events from the buffer;
• computer readable program code for communicating the at least one recovered event to the control data access server for delivery to the supervisory device;
• and
• computer readable program code for preventing deletion of the recipe control module until all events generated by the recipe control module have been journaled by the supervisory device.

A system comprising:

• a controller configured to control one or more process elements in an industrial process control system that is associated with production or processing of a product, the controller also configured to generate and store in a buffer multiple events associated with execution of a recipe control module by the controller, each event associated with a unique identifier, the recipe control module defining production or processing requirements for a batch of the product and having a set of phases, each phase associated with a sequential control module, each sequential control module configured to implement the associated phase of the recipe control module;
• a control data access server, the controller further configured to communicate the events from the buffer to the control data access server, the control data access server configured to provide secure data access to and from a control execution environment of the controller;
• a notification client configured to receive the events from the control data access server and to store the events in a notification queue;
• a notification manager configured to retrieve the events from the notification queue and to store the events in an event list;
• an event system data component configured to determine if any events are missing using the unique identifiers associated with the events from the event list;
• and
• a supervisory device configured to receive at least some of the events from the controller via the control data access server, the supervisory device also configured to initiate an event recovery by the controller and to communicate an event recovery request to the controller through the control data access server if at least one of the events from the controller is missing;
• wherein the controller is further configured to recover at least one event and to communicate the at least one recovered event to the control data access server for delivery to the supervisory device during the event recovery;
• and
• wherein the controller is configured to prevent deletion of the recipe control module until all events generated by the recipe control module have been journaled by the supervisory device.