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29/03/1999 Doc.No.V20-P123-08-A02-7218, Rev.

0 LIGNITE HANDLING SYSTEM TS1 EXPANSION, 2 x 210 MW WRITE-UP ON CONTROL SYSTEM ARCHITECTURE The control system will be based on available models of approved makes of PLC having all flexible features which are normally found in large PLCs. The total redundancy at various levels namely CPU, power supply and communication bus is provided in this design. Intelligent remote I/O modules are installed at every 150 m or so along the conveyor route length to scan the status of BSS and PCS, ZSS and Emergency Stop Push Buttons. Approximately upto 64 digital inputs will be obtained in these remote I/O cabinets from each of the above BSS and PCS, ZSS, Emergency Stop PB (in LPB) if any and other field devices, such as, chute jammed indicating contacts etc., located in the area. These remote I/O modules are capable of communicating the status input over RS 485 network with remote master located at the central PLC panel (control desk). In order to offer redundancy at these levels, each remote intelligent I/O cabinet (RIIOC) will have two intelligent CPU + power supply modules, which are respectively connected to the main bus as well as to the backup bus. Likewise, there will be two masters in the control desk, which will scan all the remote I/O modules connected in their respective network. In each local I/O network, approximately upto 64 modules are connected as stated above. Hence, two pairs of twisted cables (shielded) of the remote intelligent I/O cabinets are interconnected with their masters as shown in the enclosed diagram. By this arrangement, at any point of time, the status of all the PCS and BSS inputs is not only available in the remote I/O modules, but also in the master (as well as backup). The two master CPUs that are located along with and connected to the two PLCs namely primary and backup PLC through communication cards. The digital inputs information available through RS 485 communication is accepted by the master units are updated in the respective primary and backup PLCs through these communication ports. Redundancy at PLC level is offered by having two identical PLCs. One PLC takes the role of primary PLC while the other takes the role of backup PLC. There will be minimum two communication ports available on the PLC. One port will be available on the corresponding port to effect peer to peer communication for synchronising and also for automatic switchover in the case of primary PLC failure. The other communication port is connected to display unit. The ladder application programme developed can be loaded to the respective PLCs through these ports. Similarly, MMI software provided for the system also takes status inputs through these ports from respective PLCs. Other than remote I/Os, there are certain local inputs such as push button inputs from control desk, digital and analog inputs from HT Switchgear PCC, MCC, other field inputs, which are closer to the panel, will be directly connected to both the PLC through DI/AI termination racks. Similarly, the outputs, which are activated by the PLCs, are ORed and connected to the relay module, which in turn, drives the output. Another set of required number of outputs will be available in the PLC for generating multiplexed output for required number of status LED display in CD for indicating which of the PCS and BSS as operated. These will enable the operator to quickly understand the fault and take remedial action. Similarly, LED indication will also be available in the remote intelligent I/O cabinets per input basis where an actuation from PCS or BSS or Emergency stop push button has occurred.

29/03/1999 Doc.No.V20-P123-08-A02-7218, Rev.0 This would enable the operator to note the fault in the PCS or BSS and they can go to attend the fault and take remedial action. The required outputs will be available from both the PLCs. The multiplexed outputs are generally activated from the primary PLC. If primary PLC fails the output of backup PLC will be automatically activated, thus ensuring the system control and status inputs all the time. The field intelligent I/O modules are mounted inside IP 55 enclosure, which are installed at different locations along the conveyor. Each location is provided with a small hooter, which will start hooting if any of the PCS and BSS is activated in that location. This will attract the attention of the field personnel. The MMI software of the PLC provided in the PLC clearly brings out graphical conveyor mimic with dynamic updation of their status as well as status of PCS and BSS. Any fault is logged automatically inside and an alarm / event file which can be viewed / printed out at any convenient time. The information such as, running hour of conveyor is also maintained in the history file. The input from the BWS automatically goes into the other extra serial port. A hourly cumulative figure, conveyor overload figure, conveyor idle running period, conveyor overload data are also maintained in the PC which are stored and (if necessary) in a file for future retrieval or reporting. The real time, trending and historical trending are also displayed in the PC. Power Supply A 110V UPS power system provides power supply for all the primary, master and secondary CPU as well as the PC, printer and also for the remote I/O cabinets. Interface Wiring / Cabling All the DI/AI signals from the UCR control panel, HT Switchgear, LT PCC1, LT PCC2, LT MCC2, LT MCC3 will be received at the coupling relay panel. Through multiplied contacts (of the DIs) of the coupling relays, inputs will then be passed on to PLC. Thus, there will be a galvanising isolation between the power equipment and the control system panel at the LHS control room. However, the control inputs from the LHS CP and CD namely PB, selector switches will directly enter PLC. Similarly, the output contact from relay module of the PLC will get multiplied at the coupling relay panel which, will in, turn feed to the respective drive to be controlled from the PCC / MCC. The enclosed drawing Dwg.No. V20-P123-08-A02-7219, Rev.0, depicts the control system architecture. Other Features 1. 2. 3. The system offered shall have 20% extra memory capacity. 20% spare I/O modules shall be provided with a minimum of one of each type in main PLC as well as remote I/O cabinets. The control will be designed with software based system with the provision for additional 20% I/Os.