96 DIASYS-UP/V Distributed Control Systems for Thermal Power Plant Ryotaro Kanai’ Tomoko Takakura’ Tetuya Yamaguchi"? — Masaji Tsujitake"* Tatuhiko Goto Hideaki Emoto’ Recently, the thermal power plants save grown to larger capacity, higher temperature and pressure and utilize more advanced technology such as the integrated coal gasification combined cycle. As these plants grow, the control & monitor systems, which operate and control the plant, are going to play an important part answering the needs of higher control performance and automation. We developed the “ IASYS-UP/V series,” which is an integrated plant control system that incorporates our wealth of experience as a total manufacturer using the latest microelectronics technology, we have achieved satisfactory results. 1. Introduction ‘The demand of larger capacity, higher temperature and pressure, and more advanced system technology in thermal power plants in recent years has called for high-grade control performance. In such plants, higher grade of control algorithm and man-machine interface function are being increasingly sought for. ‘As a plant manufacturer, Mitsubishi Heavy Industries, Ltd. (MHI) has so far developed, and delivered both abroad and in Japan the Digital Control System DIASYS series for thermal power plants with high control function and high reliability to ‘meet with the needs of power plants. Among the DIASYS series, the Digital Control System DIASYS-UP/V series has the high-speed arithmetic processing capability and oper- ability improved, while keeping intact the conventionally popular DIASYS-IDOL on the basis of 180386/486 CPU. This paper describes the outline and features of this series. 2. Outline of DIASYS-UP/V 2.1 Basie conception DIASYS-UP/V is designed under the following five concep- tions, each of which is extremely important for the control system of a thermal power plant. () High reliability Similar to the conventional DIASYS series, DIASYS- UP/V ensures high reliability due to the fault tolerant design based on the design utilizing redundancy, and the severe quality control system. Further, the exclusive cards for turbine protection have been added to the card line-up to allow steady operation of the plant. (2) High control performance The powerful 32-bit processor, 180386/486, with excel Tent record in power plant industry is adopted to ensure high-speed arithmetic processing. (User-friendly man-machine interface The operator station, designed on the basis of human engineering technology, minimizes human error and pro- vides an easy-to-operate environment. (4) Easy maintenance The control logic can be easily adjusted or changed by using the easy-to-understand DIASYS-IDOL. ‘Should some error take place, itis immediately detected by the self-diagnosis function of the system, allowing easy maintenance of the system per module. (8) Extensive flexibility and extendability ‘The unit-wise distributed design befitting with the master machine ensures a wide range of flexibility irre spective of the plant scale, and also enables easy extension of the system in the future, 2.2 System configuration Fig. 1 shows the system configuration. In DIASYS-UP/V series, the memory capacity and I/O marks are set to the scale ff allowing the unit-wise control of the master machine ‘components such as boiler control, turbine control, and burner control to comply with both the integration rate for making the effective use of CPU capacity and the distribution rate for allowing the extendability. The system in smallest scale is composed of one unit of control station and one unit of ‘operator station, leaving sufficient room for the extension of plant in the future by adding more machines. A maximum of 50 pieces of component elements such as control station, operator station, etc. can be connected to the unit network, and a ‘maximum of 40 000 points of process inputs/outputs including the inputs/outputs from outside and the inputs/outputs from gateway can be set per control station, 3. Funetions ‘The main system components and functions of DIASYS-UP /N are given below. . na gg system Two arte Ut tet es mater cane stn Fig. 1 DIASYS-UP/V typical system configuration 7 Power Systems Engineering Center, Power Systems Headquarters 42 Nagasaki Research a Development Cente, Technical Headquarters 45 Nagasaki Shipyard & Machinery Works 1 Kobe Shipyard & Machinery Works #5 Takasago Machinery Works Mitsubishi Heavy Industries, Lid Technical Review Vol.34 No.3 (Oct. 1997)3.1 Control station ‘The control station carries out automatic control and input output processing of the plant. The station is designed to meet with a wide range of applications from control of turbine burner requiring high-speed arithmetic processing and auto- ‘matic control of boiler to control of automatic start/stop of the plant. The system configuration of control station is shown in Fig. 2. The control station is composed of CPU card for high- speed arithmetic processing, PI/O card for interface with ‘monitoring and controlling operation signal, and IOC card for controlling LAN and PI/O card. The CPU card is used collectively with 10C card. ‘The INTEL Co.-made i80386 and 180486 with high process- ing capacity are used as CPU. The LAN interface function, 1/ control function and RAS interface function are all integrat- fd in the CPU board, which was considered indispensable to the distributed control system, ensuring more compactness and Fig. 2 Typical system configuration of control station 97 reducing the overhead. The input/output section is composed of a group of exclusive cards connected to the LBS network developed by MHI using portable HDLC for protocol or Arcnet, and the reduction of elements and power consumption allows compact processing of a large number of input/output points, while the combination with CPU cards ensures high reliability and maintainability. The sources for card supply are all unified to a simple power system of 24 V, and double power units are used to ensure high reliability, ‘The noise resistance is further improved by insulating not only the field signals of PI/O cards and common power units, but also the digital signals, analog signals, measurement signals of cards and the voltage converter required for communication, ‘The main hardware elements are given in Table 1. 3.2 Operator station This is man-machine interface unit that carries out monitoring and operation of the plant. There are two types available: work station type and personal computer type. The adoption of high-resolution full graphic color CRT, and X window or Windows as GUI (Graphtical User Interface) has enabled wide and effective use of window display, contributing to the improvement of man-machine interface. In order to provide the operator with a large amount of information at fewer manipulations and to allow the operator to respond quickly and promptly, special functions of the plant manufacturer such as Operation Guide, ete. are adopted to ‘support the operator, Table 2 shows a list of such functions, land Fig. 8 the screen of operator station. 3.3 Data logger system The data logger system is a device for collecting and preserving the plant data, with the preserved data transmitted to trend display in operator station or through various form prints. 3.4 Control function ‘The control operation is described by using DIASYS-IDOL, the control logic description language exclusive to DIASYS, The conventional digital controller needed programming technology to build up the control logic, and was difficult for control engineers to handle, while in the case of the DIASYS- ‘Table 1_List of main hardware element —a Par amber Deron Caras for CPU at] MBCPU UT) SE wi wi Hagman ion Doce ol |i ses wen st gna funtion ‘Corsminicaon rd | MBETH OT —[Btheret communcation EXEC 0) | Optic! ceca! comerin it Matas 02 | Phoraseetne tanafer © MULTIBUS 1 8S UF INBLBS 02 _| Sena communication, photoeloars Wander L8S UF Pd arae NAIM b2 —| Thermocouple ips: pitveara RTD inp | point ard or bro pin competion (tS sere) NBAOMCOL |t todo ma op» pi care, Noi ot | ig! inp 3 potlear INBPIM O1 | Pulse apt 8 pors/cara INBDOM s2_|Digtal outa 3 pote card WO sesral rd ——[oatoe [i woes CPO wih sel Siagnons Fnsion Arent communication snd P/O ietace PLO ears OAT ot te 0 mA input 18 pirtefeard to 5 V, thermocouple, RTD out (hrot sein [DaaOnear [tt 20 mA eaga:e poitalcar 0010 V [babii [Dig ipa pointe eare Ibabost'c: [Digest on fpr [bas ot [AMI sexton VF cor for servo valve @ cheaed) Ibosva 82 | AVI satin /F eae for forge motor @ ena) [DoeDt ot [Dig input (wih event record functions 2 pomeseard.2¢ V [DoeDI [Dig iput ith even record futon” 32 pn/crd ene DI card, 2 point, 8 V [BOVIF oi [Vale inertace Al, AO" ¢ plots DI, BO: 8 pins, 4 [DoVIF t2_|Valve terface AIL AO: folotsDI. BO: 8 po 8 V “Taine aeriock cards [DOIOM Of —]Prograneable nero catd fo turbine governor POEOS 0:_| lecvieal oer sped tig cee or trine governor Mitsubishi Heavy Industries, Lid Technical Review Vol.34 No.3 (Oct. 1997)98 5 of operator station [Sex eee ee Saye Oy aang pines of coal oro Dipiane§ pees of conta lope ands aod for gla gaTon Dapave eral ths plank operation satus DapaysgrpBiealy he tse cage of process a Dapats Coreonthp been to process cts ttn tnt a xo | 0 oor Diiays ALARM deat Oy dis loge’ system [gine aban mesage scorn tobe ange ac a Stores and celays 3 maximum of 1600 crete such as ALARM [ON/OFF START/STOP of auxary machines Reyer Torna forcalelton sig procs at, sO SS ee Eco sire rao Ren Santee Fig. 3. Sereen of operator station (graphics) IDOL, the program code is formed simply by drawing. the conventional control system diagram on the CRT screen, This is a control operation software developed originally by MUI for thermal power plants, and has gained high reputation from the customers for easy description of control algorithm. Ever since it was developed in 1980, the DIASYS-IDOL has maintained the interchangeability in expression method, but has become more speedy and compact in terms of arithmetic processing method, ‘The DIASYS-IDOL contains 81 standard logic elements, with the typical 6 elements shown in Fig. 4 The elements are displayed for selection on the screen menu of “logic create/modify” of the engineering workstation. Further, the standard elements can be combined to form a new element by using “user definition macro function.” 3.5. Engineering workstation The control logic, drawn by using the DIASYS-IDOL, is prepared and maintained by using the engineering workstation. ‘The main functions of the engineering workstation are given below, and the typical screen in Fig. 5. © Creating and modifying of control logic, real time monitor- ing, and on-line parameter tuning ‘© Suspending individual elements of control logic operation, opt af | ue a tout 2b oot 2 opt 3 roti Paloma Pate Earl of ent having reins | tn Beaver regan | mee mE AML ana 5, Loum oa 201 Tracing Uap it Fig. 4 Typical DIASYS-IDOL elements Mitsubishi Heavy Industries, Ltd. Technical Review Vol.34 No.3 (Oct. 1997)Fig. 5 Screen of engineering workstation (diagram monitor) Table 4_Network specification Sa eer ar S Tommaniestion TSMACD | Token pasting Boring sleting Seeccaton—_[cmovig wh EE ccg waster | Png es etworefoptogy—[ Bax tr — [a pe: Stare — Toop Ceministon 10 Mg 25 ie TS Mb Sel Fria eral etl ol] Pate HDL Pepi reml | som tots | ioomtcis | Wamwis and setting temporary output Creating and transmission of foop data On-line collating of control logic Displaying a list of signal names Trend display Tuning history display Static characteristic data collection and data System status display. 3.6 Reliability of the system ‘The DIASYS-UP/V series are designed on the basis of redundant system configuration, where an authentic self- diagnosis function, and a quick backup switching function at the time of error detection are major elements. (1) Self-diagnosis function ‘The list of self-diagnosis items are given in Table 3. (2) Double-switching method ‘Should an error appear in CPU/IOC unit, the monitoring routine immediately detects the error, before the system gets automatically switched to the stand-by CPU/IOC unit, to continue the control 3.7 Network ‘The hierarchical configuration of the network of distribut ed control units and the network within the control units allows the distribution of load at the time of data sending and receiving, and the distribution of risk (danger) as well () Unit network ‘The superior (master) network connecting control station, engineering workstation, operator station and data 99 Table 3 List of self-diagnostic items tg Bas ine ak ear — Memory parity roe ncoree mrtg CPU oct top wor error Powe supply vlage fo i Bas tine out err Inco aaa (CPU cock stop Wo clock tn Power sup rltage lon Toes bas er ewan CR cies Power suply unt Power spy Toss Gelunint power Sy Ta Base wtrare Division by sero UNTO) reaping (NT) Bocods cack NTS) Invaiéopende INT) Deve not avedabe NT Dosbie faut 1879) valid TSS (INT) Segment ot present CNTID) Steck fae NTI) Geverat protection NTIS) Page ea TIO Floating pont err 0NTI6) Aliment hac UNTIZ) Toop data ere Loop operation ror Ipconatency of top data tween dilex CPU) Eberet tratuniaion evr Exnernet reception eer ‘Abnormality at PLO card ARCKET tranminion error |ARCNET recep eor Tescking vor “Tapia wware —] logger system is called “unit network,” and the Ethernet complying with IBEE 802.3 is adopted as the unit network in order to realize high-capacity and high-speed communi cation. The network specification is shown in Table 4, (2) Local network ‘The control station and the 1/0 unit are connected by ‘Arcnet or LBS to carry out compact processing of a large ‘umber of input/output points, and to allow easy expansion of the system. The specification is shown in Table 4 4. Conclusion We are determined to adopt the up-to-date electronics technology in DIASYS control system in order to promote higher speed and downsizing of CPU, and to expand it to an integrated system by combining all functions from high-degree control function to man-machine interface function. We are also determined, as a plant manufacturer, to provide our customers with more active operating technologies and equip: ‘ment protecting technologies such as remote sensing, on-line diagnosis through remote maintenance, etc. by making the effective use of the new generation communication media, and with a wide range of other services. We will keep on making incessant efforts to supply the control system, “user friendly” and with “high reliability” and “high performance,” while matching with the main machine of the plant. Reference (2) Isomura, S., A DDC Software for Power Plant Control (DOL: Interpreter DDC Oriented Language), Mitsubishi Heavy Indus tries, Ltd. Technical Review, Vol18 No.3 (1981) p.192 ‘Mitsubishi Heavy Industries, Ltd. Technical Review Vol34 No.3 (Oct. 1997)