Third Generation: The Extended Automation DCS

Today’s power generators are faced with intense pressure to improve production
reliability and bottom line profitability. As a result, current business goals focus on
increasing operational efficiency and overall equipment effectiveness (OEE). In
support of OEE — a tool used to identify production loss and asset availability —
third-generation DCS employ powerful object-oriented design technology to
enable efficiency improvements within daily operations and maintenance (O&M)
activities.

Additionally, advanced process optimization technology is added to support

improvements in process efficiencies such as power plant heat rate. Asset
optimization is available to improve production reliability through improved
process stability as well as through asset monitoring for predictive maintenance.
Control system technology also now integrates several fieldbus protocols, thus
enabling more flexible plant designs as well as improved data for maintenance.
An example of a third-generation DCS is ABB’s Industrial IT System 800xA.

Aspect System Technology. Embedded within the 800xA DCS system’s

platform core is a new object-oriented technology called an "aspect system."
Aspect system technology provides an enterprise-wide data management tool
within the DCS operator’s console. It allows plant O&M information to be directly
linked to DCS graphical objects. This means users with secure access to the
DCS screens (such as plant operators, maintenance personnel, and managers)
can get personalized views of important plant information. Providing the right
information to the right person at the right time for informed decision-making
saves time and thereby improves operational efficiency.

"Aspect links," which are simple, menu-driven links to O&M information, can be
launched via mouse click from DCS graphical objects, alarm points, or a
controller configuration drawing (Figure 1). Aspect links of interest to plant
operators may include alarm decision system information, operational help
screens, live video feeds, start-up instructions, and trends. Links of interest to
instrumentation and control personnel may include detailed troubleshooting
information such as plant piping and instrumentation drawings, equipment O&M
manuals, application guides, and smart device management tools. Links used by
maintenance management may include work orders, fault reports, or spare part
inventories.
1. Linked up. Improving the efficiency of plant operations and maintenance, the
800xA distributed control system (DCS) provides aspect link technology for
navigating to important plant information from DCS client screens. Source: ABB

Permissions can be configured to manage individual views into the aspect links,
thereby ensuring that system users can only view information relative to their
specific job function.

Process Optimization and Asset Optimization. To support the goal of

increased plant process efficiency, advanced control can be added to the DCS
using model predictive controller (MPC) technology. The MPC approach provides
a multi-variable algorithm that runs at a much higher frequency than earlier
optimization techniques (typically, cycle times are measured in seconds, rather
than minutes). The result is an accurate process model that can be added to
base system controls to produce less variability and smoother transitions. Less
variability typically enables processes to operate closer to equipment design
limits, therefore enabling significant improvements in steam temperature, ramp
rate, heat rate, situations with complex coordinated control, and reduced
emissions.

Asset optimization, now available within most third-generation DCS designs,

facilitates increased OEE and avoids unplanned shutdowns, thereby increasing
plant availability. Asset optimization can also extend the life of plant assets by
using advanced predictive maintenance techniques. For plant assets, a logical
analysis function called the "asset monitor" provides 24/7 supervision of the plant
device or process. Assets that can be monitored include DCS components,
communication networks, smart instrumentation, process control loops, pumps
and drives. Power plant processes such as feedwater heaters, water quality, and
heat exchangers can also be monitored. Asset monitor options can be scaled to
include any number of assets, from plant to fleet

By applying object-oriented technology, asset optimization is seamlessly

integrated with commercially available computerized maintenance management
systems (CMMS). From the DCS process graphics, plant maintenance staff can
get an asset management view of the plant to access work orders, spare part
inventories, and maintenance activities. They can also rely upon the DCS to
identify problems and automatically generate a fault report for automated
download back into the CMMS.

Expanded Connectivity for Process Control. Third-generation DCS controllers

and I/O hardware occupy much smaller footprint than earlier systems. DIN rail
components operate using 24VDC and can be routed via redundant fiber optic
networks. This makes for a more scalable solution, as it is much easier and
economical to physically distribute clusters of remote I/O throughout the plant.
DCS controller technology has also evolved to support SIL 2 and 3 standards for
safety as well as the traditional National Fire Protection Association 85
requirements applied to many utility applications.

Integrated fieldbus is a significant third-generation DCS enhancement. In

particular, bussed communication reduces field wiring, and provides beneficial
data for asset management. Because the technology allows mixing bus protocol
connections within a common controller, it gives plant designers great flexibility
for plant layout and final control element device selection. Today’s control
systems support the integration of many protocols, including Profibus,
Foundation Fieldbus, Device Net, and IEC 61850.

IEC 61850 is a recent development that is used for electrical system integration
into the plant DCS. With capabilities of integrating intelligent electrical devices
(IED) for control and asset monitoring and device management, the IEC 61850
standard is emerging with connectivity options for protection relays, drives,
medium- and high-voltage switchgear, and other equipment. Also, specifically for
power plant applications, DCS controllers can integrate field-bussed specialty
cards for turbine control (overspeed, auto synch, and valve position), vibration
condition monitoring, and flame scanners.
Finally, thought they’re not classified as fieldbus protocols, the highway-
addressable remote transducer (HART) and Modbus over Ethernet have also
been more tightly integrated into the third-generation DCS controller level (Figure
2).

2. Extended automation DCS. Third-generation distributed control systems offer

many options for connecting plant process instruments and devices using
fieldbus, Ethernet, and wireless technologies, as well as through traditional
hardwired I/O systems. Source: ABB

Engineering Tool Enhancements. The DCS software interface employs object-

oriented technology to provide user-definable "library objects." This approach
allows complete control strategies — such as motor-operated valve control,
faceplate, graphic element, and aspect links — to be packaged into a single
library object that is available as an element within the project library.

As an object is used repeatedly throughout a project, it maintains its reference

"inheritance" to the original library object. This allows for a consistent design
approach for all similar plant devices and also simplifies maintenance of control
configurations when code modifications are required. Control programming
methods are available to support function blocks from previous first- and second-
generation DCS systems as well as IEC version function blocks, ladder logic,
instruction list, structured text, and sequential flow charts.

Improved Power Plant Simulators. When used for operator training, simulator

systems typically provide a substantial opportunity to improve plant operational
efficiency and expertise. Simulators can also serve as testing grounds for
verifying DCS logic changes. In earlier DCS generations, power plant simulators
offered controller hardware-based "stimulated" or PC "emulated" simulators. The
latest DCS simulator technology provides a "virtual controller" PC-based
environment for running the original equipment manufacturer (OEM) version of
the controller configuration.

The virtual controller is easier to maintain than the previous-generations’

hardware-based stimulated simulators. Furthermore, when combined with the
OEM HMI and actual operator process graphics, the virtual controller approach
provides the most realistic simulation system environment and can be easily
coupled to a range of low- to high-fidelity simulation process models.

Future Enhancements

DCS system capacities and controller performance will continue to improve, therefore enabling even
higher I/O quantities per controller from both hardwired and integrated fieldbus paths. Continued and
more widespread use of DCS electrical system integration using the IEC 61850, Profibus, and Profinet
industry standards is expected.

Regarding the physical layer of fieldbus technologies, one would expect that all standard protocols will
evolve toward a redundant high-availability Ethernet for fieldbus trunk networks. This would allow a
common industrial Ethernet field network to be run to all areas utilizing fieldbus instruments and
electrical gear and would eliminate the need for multiple media types when various bus protocols are
used. The need for less-protocol-specific cabling would result in a more cost-effective plantwide wiring
scheme.

Also anticipate increased use of wireless technology for instrumentation using standard protocols and
perhaps mesh networks for the integration of communication devices within the DCS for control as well
as for asset optimization.

For the foreseeable future, DCS application software will continue to provide new strategies and
features in support of plant goals to improve operations, process production, and reliability. The
addition of information systems that enhance the retention of staff expertise (a necessity in plants with
an aging workforce) will result in operational improvements and support efficient plant operations.

We also anticipate the increased deployment of asset management with process-related asset-
monitoring objects that are specific to power plants. Computerized maintenance management
strategies within plants will also improve reliability.

As business demands may pressure power plants for production increases, there also may be new
motivations to apply advanced optimizing control applications. For example, as more electrons entering
the electrical grid are produced by sometimes less-predicable sources, such as wind and solar energy,
new operational requirements may be imposed upon existing generating units. Situations such as this
can drive future plant adaptations that may benefit from optimized control or advanced control
combined with electro-mechanical modifications to support variable-load optimization.
–Ralph Porfilio (ralph.porfilio@us.abb.com) is the director of technology and applications engineering
with ABB’s Power Generation North America Division (www.abb.com), and ABB Inc. company.

DCS Security and the Open System

With today’s "open" DCS systems, care needs to be taken to include security measures that can be easily integrated into a
owners’ overall security strategy.

Critical infrastructure protection (CIP) regulations developed by the North American Reliability Corp. and sanctioned by th
Regulatory Commission have spawned many DCS and SCADA security-related organizations, committees, and discussion g
DCS security poses new challenges for plant owners as well as DCS vendors.

From the plant owner perspective, security procedures need to be documented and adopted by system users, especially t
Procedures need to be enforced, maintained, and updated whenever changes are required. For tracking system changes,
provides a new audit trail feature. Modern DCS systems are capable of supporting secure configuration at many levels (inc
network, operating system, engineering tools, user access to stations, individual control screens, aspect links, faceplates,

As plant owners tailor security procedures to support plant-specific and fleetwide goals, the third-generation DCS system
adaptable to support a wide range of customer-specific strategies.
Emerson Automates Stage II of NTPC’s First Coastal-
Based Coal-Fired Thermal Power Project
Emerson’s Ovation™ technology will help NTPC produce power for India’s
Andhra Pradesh, Kerala, Tamil Nadu and Karnataka states

HYDERABAD/DELHI (APRIL 23, 2012) — Emerson Process Management

announced today its successful completion of the automation package for the
NTPC Simhadri Stage II 2x500 MW super thermal power project.Located near
Visakhapatnam, it is NTPC’s first coastal based coal-fired thermal power project.
The plant’s output is expected to reduce the power deficit significantly in four
southern states: Andhra Pradesh, Kerala, Tamil Nadu and Karnataka as well as
in the Union territory of Puducherry.  With completion of the project, NTPC
Simhadri is regarded as one of the most modern power plants in India with state-
of-the-art control and instrumentation systems. Emerson is the station control
and instrumentation (C&I) systems contractor for this plant. 
Emerson’s control and instrumentation technologies will play an important role in
the operation of a power plant by helping it achieve maximum availability,
reliability, and flexibility. The facility will use Emerson’s distributed control system,
Ovation™, to monitor and control various plant areas and help to ensure that the
plant operates efficiently and reliably. As part of the automation package,
Emerson installed more than 50 Ovation™ controllers and multiple workstations
across various power plant areas which will manage approximately 30,000
input/output points to monitor and control the station and main power plant. The
system’s ability to control operations more tightly is key to achieving and
maintaining super thermal unit efficiency.
In addition, Emerson has installed the Distributed Digital Control & Management
Information System (DDCMIS) for the power plant, along with measuring
instruments, UPS, LVS, CCTV, PA system, Instrumentation/control cables, 24 V
DC battery system and PlantWeb components.
Other Emerson Process Management technology offerings installed as part of
the plant automation include its comprehensive range of Rosemount™
measurement equipment, an additional layer of wireless data highway and a
software package for enterprise-wide plant performance reporting and decision
management. This helps in measuring and reporting performance in the plant,
anywhere anytime.
“NTPC, a Maharatna firm and leader in power generation, understands the
importance of choosing the right automation technologies for super thermal
power plants,” said Amit Paithankar, Vice President & Managing Director,
Emerson Process Management India. “Emerson was best equipped to provide a
total solutions package that not only met NTPC’s interface specifications but also
all its process control goals.”
For more than 30 years, Emerson Process Management has been providing
industrial customers in India with advanced technologies to control critical power
generation processes, increase plant efficiencies and megawatt production, and
realize long-term operations and maintenance savings. Emerson has won orders
for over 15 supercritical thermal power plant units in India due to its global
expertise in executing complex and demanding projects at supercritical thermal
power plants.
About Emerson 
Emerson (NYSE: EMR), based in St. Louis, Missouri (USA), is a global leader in
bringing technology and engineering together to provide innovative solutions for
customers in industrial, commercial, and consumer markets through its network
power, process management, industrial automation, climate technologies, and
tools and storage businesses. Sales in fiscal 2011 were USD 24.2 billion. For
more information, visit emerson.com.
About Emerson in India 
Emerson’s sales in India were approximately USD 700 million in fiscal 2011. The
company has more than 8,500 employees across the country who are involved in
manufacturing, global engineering, project management, sales and service.
Pradipta Sen is president of Emerson’s India, Middle East and Africa region.
About Emerson Process Management
Emerson Process Management (www.emersonprocess.com), an Emerson
business, is a leader in helping businesses automate their production, processing
and distribution in the power, chemical, oil and gas, refining, pulp and paper,
mining and metals, food and beverage, life sciences and other industries. It
provides advanced distributed process control and information systems, and is a
recognized leader in developing plant-wide process control solutions for the
power generation, water treatment and wastewater treatment industries.
Emerson combines superior products and technology with industry-specific
engineering, consulting, project management and maintenance services. Its
brands include PlantWeb™, Ovation™, SmartProcess™, SureService™,
Syncade™, DeltaV™, Fisher®, Micro Motion®, Rosemount®, Daniel™, and
AMS Suite.
Utilities have already invested in technology and digital
innovation. However, there is still a treasure-trove left to
be discovered including IoT and artificial intelligence,
says Graeme Wright

The world has seen three industrial revolutions take place, all
of which have changed the face of industry. Each time a
change in the factors of production has taken place: labour to
energy, financial capital to intellectual capital and now land to
data.
Now we are in the midst of a fourth, which is unequivocally
our most advanced and technological revolution yet. The rate
of change even over the past decade has surpassed
expectations. Moore’s Law, for example, which once set the
pace of technology’s advancement, is now on the cusp of
becoming obsolete.
We are in an age when technology enables us to pay for items
with the touch of a fingerprint, cars drive without drivers and
even cows are connected to the Internet of Things. Technology
is at the epicentre of our world and, from banking to farming,
there is no escaping how it touches our everyday lives. One
sector that is not exempt from this digital transformation, but
perhaps goes under-recognized, is utilities.
Utilities companies are on a constant quest to improve safety,
effectiveness and efficiency in an increasingly complex and
regulated sector, and are on the hunt for new tools and
technologies to help them achieve this. According to our
research, Technology in a Transforming Britain, utilities
companies are embracing innovation and technology to help
drive their business and the sector forward.
It seems, however, that this is unknown to the UK public, as
only 7 per cent believe the industry is most responsible for
driving the UK forward and innovating to improve life. The
findings reveal 84 per cent of utilities leaders are positive
about the change that technology is making in their
organizations, and suggest IoT (42 per cent), wearables (40 per
cent) and artificial intelligence (AI) (40 per cent) will be
implemented in the next 12 months. Utilities is one of the top
sectors for investing in these innovations.
When it comes to consumer awareness of innovation, it is
often limited to smart meters and home devices such as Hive.
It is not surprising, therefore, that consumers are unaware of
the investments and innovations that utilities companies are
making. For most utilities companies, the innovation that
occurs is behind the scenes, helping to underpin the
infrastructure of utilities and how energy and water are
delivered, all out of the public eye.
IMPACT ON THE FUTURE WORKFORCE
Perception is everything, especially when it comes to
recruiting talent. With a new generation entering the
workforce, they will look to work for industries and companies
that are digitally advanced, driving innovation and provide the
same level of technology they experience in their day-to-day
lives. The perception therefore from consumers that the
utilities sector isn’t technologically savvy or driving forward
innovation could result in fewer new entrants into the industry.
If the industry is to continue to move forward and see success,
not only in terms of innovation but as a magnet for top talent,
it needs to demonstrate that it is not comprised of working in
silos with just a toolbox.
Up until now, many of the IT and technology functions within
utilities organizations have been very focused on the
digitalization of the back office. The attention here has been on
improved call handling, better billing and financial
management of assets.
In the field, there has been less progress – for example,
enabling engineers to be safer with technologies such as AR
has only recently progressed. This has resulted in the public
impression being that the utilities sector is undeveloped and
lacks digital innovation.
The traditional IT function hasn’t got to grips with how the
people in the field work. For the sector to advance, there needs
to be a change in approach, with greater focus placed on the
activity of those on the front line and how technology can be
used to make their work what I call ‘frictionless’.
Even simple changes such as a more apparent use of connected
devices for making calls and sharing data and information
when in the field can have a significant impact on employee
efficiency. Utilities companies can harness data to improve the
engineers’ output and enable employees to do the job better,
faster and with more reliable information. This can alter the
perception of the sector, demonstrating it as a more dynamic
workplace and helping to attract more talent to the sector.
So how can technology help transform utilities as a business?
THE SHARING OF KNOWLEDGE
Technology can be a fantastic facilitator for sharing
knowledge, skills and expertise. Thanks to an aging workforce,
combined with a new generation entering it, the industry faces
the challenge of a knowledge and skills gap.
With portable devices, vastly better wireless communications
and the ability to provide two-way video, younger, more able-
bodied engineers can call upon the expertise of older and more
experienced engineers, who may not be able to physically
perform the same tasks anymore.
AR mounted head displays – whereby a hardhat enables a two-
way video call – can effectively provide over-the-shoulder
advice from engineers situated at another site or head office in
a safe and effective way. Not only does this provide the next
generation with the skills needed for their role, but it also
enables soft retirement and offers a place for staff who are of
retirement age, but still enjoy working.
THE CONNECTED UNIFORM
Another area the utilities sector can benefit from is wearables.
By adopting wearable technologies, utilities companies can
help to look after their workforce and empower employees to
look after themselves better. It is important, however, for
employees to view such technologies as being there to help
them, without being perceived as a Big Brother initiative.

Let’s look at driver drowsiness for instance. For many

engineers, driving long distances to different sites is part of the
job description. This can have a big impact on their energy
levels, resulting in tiredness and fatigue. A driver drowsiness
device can monitor the pulse and movement of the driver and
alert them when there is an increased level of risk. This results
in maintaining the driver’s level of alertness and helping them
avoid drowsiness when accidents may occur.
Monitoring the vitals of engineers is another great example –
whether it be tiredness, stress levels, overheating or when a
break is needed. Through monitoring of many factors,
engineers can take steps to manage their wellbeing and take
the rest they need in order to ensure they prevent any accidents
related to their health and vitals. All too often we have seen
that lone worker solutions, in the past, only enable the
reporting of incidents, e.g. fall detection, rather than help staff
to be aware of their body and take the right actions to avoid
problems.
By using such wearable devices, over time the behaviours of
engineers and other workers in the field can evolve to create a
safer working environment, minimizing risk.
Through this communication and frictionless flow of data
between employees and the companies they work for,
companies can be continuously aware of their employees’
wellbeing. This in turn can help them identify where and when
employees may be at their most vulnerable to injury. As a
result, companies can make changes to working conditions and
hours and can make their workforce more rested, content and
efficient in the process, a far more robust approach to health
and safety.
IOT AND AI
The conversation around IoT has changed. Previously, it
simply focused on sensors and connecting any number of
‘things’.
The challenge, however, was that people and companies were
not thinking about what these devices were being connected to,
how and where the data is collected, where it is processed, and
then what to do with it. Utilities companies have had a wealth
of data for many years thanks to the multitude of systems, but
until now it was rarely used across the business as it resided in
operational systems and often never left the location where it
was generated.
However, as we move into the era of AI, utilities companies
can now begin to make sense of, derive value from, and act on
the data in real time.
Whilst ‘machine learning’ is currently being used to encode
the rules of past events and anomaly detection is a key area,
utilities companies can use their data to analyze machinery and
identify what may lead to a problem and prevent it before it
does. However, the development of deep learning systems will
likely lead to a step change in the nature of work, improving
the efficiency and services of the business and consequently
increasing its productivity.
Sensors, for example, can monitor devices and appliances and
issue an alert in real time if they are going to fail or become
inefficient, automatically calling out for an engineer. This will
save both time and money for companies and the customer.
Customers will be able to have maintenance performed on
their appliances before any damage occurs or service is
interrupted, and for the utility companies themselves, this real-
time efficiency will enable an increased level of productivity,
changing the way they work from time-based to condition-
based maintenance.
The engineer can then focus on making things continue to
work rather than fixing them once they have failed. A
connected workforce can prioritize the assets that need to be
looked at rather than having to regularly monitor assets that are
working smoothly, which can be an inefficient use of time,
money and personnel.
NEW BUSINESS VENTURES
Technology is having, and will continue to have, an
undeniable impact on the utilities sector, bringing better and
safer ways of working as well as improving efficiencies for
both companies and employees. But why stop there?
As utilities companies continue to harness technology and
innovate their business infrastructure, they will unlock new
opportunities for their business.
Not only does this offer the opportunity to increase revenue,
but it also ensures the entire service a customer needs from
maintenance, spares and expertise and delivers a new business
model and payment profile for utilities companies to add value
to their services.
Utilities companies have already taken steps when it comes to
investment in technology and innovation. As we have seen, the
sector is surpassing some of the UK’s more thought-of
industries when it comes to driving the digital agenda forward.
But there is still a treasure trove left to be discovered. By
taking the time and investment in innovation, the utilities
sector can transform itself to meet the digital 21st century.
With a focus on making technology, work and the 
flow of information ‘frictionless’ using new IoT and wearable
innovations, companies can improve employee safety. By
providing better monitoring of people out in the field, real-time
incident reporting and analytical insight into areas of risk,
performance and environmental factors, we will see greater
predictability, affordability and resilience of the services
provided to the public.
Companies can profit from increased efficiencies by
supporting them with new and improved digital tools, which
can enable employees of all ages to continue to share and grow
their expertise and deliver a collaborative working
environment. It is through technology that utilities will evolve
and will help build a connected infrastructure, which in turn
drives operational excellence and secure its future.
Changes in power generation are being driven by politics and economics as well
as advances in technology.
The political imperative to restrict carbon emissions is being felt across the
developed world, leading to unprecedented investment in renewable energy
technologies.
New intermittent sources of power mean that conventional thermal power plants
must operate more flexibly, which places additional demands on processes and
components. As power generation technology evolves to meet 21st century
requirements, rapid advances in the field of electronics have transformed the
reach and remit of central control systems.
A power station contains hundreds of valves in a range of types and sizes, each
controlled by an actuator. Valves may be used to stop and start flow, reduce or
increase flow, control the direction of flow, regulate a flow or process pressure or
relieve a pipe system of a certain pressure.
The fundamental design of the valves has not changed much in the last decades,
but the requirement to operate at increased pressure, temperature and/or
frequency has been aided by advances in material technology and manufacturing
techniques.
The actuator is an interface between the valve and the control system that wants
the valve to move at a specific time or speed or opening rate. Plant efficiency
requires that this process is controlled as accurately as possible. The basic
design of the actuator – a motor mounted to a gearbox which drives the valve –
has also not changed much in the last 30 to 40 years. What has changed is the
control and operations of the actuator which has been transformed by continuing
developments in electronics.
Valves and actuators suited to the demanding environments of a power station
are classified by their level of complexity. The simplest arrangement is an on/off
actuator for a valve that is either open or closed and that operates infrequently. A
Class B valve can be shut, part-open or fully open and also operates
infrequently. Class C combinations can provide frequent operation and
modulation while class D valves are required to operate continuously. Older
baseload power plants in continuous operation relied mainly on the lower class
valves but modern plants required to operate more flexibly rely on more
sophisticated modulating valves and actuators.
Modern actuators can be monitored and directed from distant control rooms and
are capable of collecting and transmitting a host of operational data which
informs both production and maintenance requirements. In line with many other
components, the trend is for an increase in the volume and type of information
exchanged.
Refining human machine interface
Developments in control systems have led to a rapid increase in the range of
data available in the control room. Advances in the interpretation and
presentation of this information have followed.
Steffen Koehler of SIPOS Aktorik, a global supplier of electric actuators and part
of the AUMA Group, talked to PEi about the company's approach to improving
the human machine interface (HMI) in its newly launched SIPOS SEVEN electric
actuator range.
He stresses that intelligent actuators need to be selected and configured for
specific applications. His company was keen that the product replicated the
accessibility and interfaces used in devices such as smart phones.
"Talking to control systems is almost like talking different languages, but though
we are operating in an industrial environment, technology has infiltrated so many
parts of our lives that we all expect intuitive, state-of-the-art interfaces."
The aim was to develop clear accessible interfaces that can use be used by
technicians and non-specialists alike."We are talking user friendly. That was one
of the big motivations. There used to be a lot of 'press buttons' but we decided to
take a whole new look at this. We considered touch screens but opted instead for
a big colour display with screens that are easily understandable.
"A large, programmable colour display means that the customer can have an
easily read status screen. Different skins mean that different software functions
can be easily viewed. Graphics, icons and animations make it much easier for
the user in front of the machine to understand what they have to do."
The graphic displays can be used to replace the instruction manual. They have
the additional advantage that they are available in over 30 languages, including
Chinese and Arabic. The computer graphics will notably come into their own
during the complex process of commissioning, showing the sequence in clearly
defined pictures.
The front end interface has been researched and designed for maximum ease of
use. Extensive tests were carried out with a usability centre – for example eye
trackers were used to establish where people look when they want information.
Discussions took place with sales people from across the globe and customers
and colleagues from various plants were invited to try out the software before the
design was finalised. The aim was to design a front end that would provide the
information in an easily accessible and appropriate format.
Ease of use extends beyond the control room with a USB interface integrated
into the system so that information can be uploaded, downloaded or copied
directly to the actuator.
"Everyone now is used to using a USB stick or USB connection. If you want
information direct from the actuator you do not want to have to have a special
tool or computer – you want to go to it and use the USB stick. We have
integrated a USB interface which is accessible from the outside and is
submersible so that, even if the actuator gets flooded, you don't have a problem.
If you want to change settings and the actuator has not been connected
 electrically to the mains power, you can use a USB battery pack to enable you to
make the process control settings."

tuators communicating via PROFIBUS DP with a Siemens DCS at ERZ Zurich combined heat and power plant

System integration
The primary function of an actuator has always been to open and close the valve.
However development of increasingly sophisticated control systems in
combination with intelligent actuators has introduced vital additional roles for the
actuator in communicating information used for diagnostic and maintenance
purposes to the distributed control system (DCS).
An actuator has different interfaces. The mechanical interface with the valve
defining torque, flange size and output speed, and its established engineering
practices is well documented. The interface with the environment means meeting
specifications and standards for vibration and temperatures encountered, for
example. The connection with the DCS is provided by an electronic interface for
communications.
The family of industrial computer network protocols used for real-time distributed
control is called fieldbus. This was designed to replace point-to-point links
between field devices such as actuators and their control systems with a digital
single link capable of transmitting all the information.
Intelligent actuators have more capability than traditional actuators and can
provide diagnostic information to monitor conditions and help diagnose and
locate device faults. Integrating fieldbus into such actuators enables the devices
to provide additional benefits such as remote diagnosis but also remote device
configuration and testing.
In modern power plants a large number of different data and information
packages need to be exchanged between control systems and field devices.
Reliable and smooth system integration is vital to ensure the communication
protocols and data interfaces operate accurately.
Years ago before standardised systems and standards were internationally
agreed, the first protocols were devised by companies pressing ahead with their
own designs. A few of these are still in use, but they exist as closed and
proprietary systems, relying on one dedicated single supplier. Manufacturers and
operators are converging on the use of standardised systems which are being
increasingly used worldwide. This gives end users and consultants freedom of
choice of suppliers.
System integration of communication protocols has become a key issue when
customers select actuator suppliers for modern plant installations. It is no longer
just the mechanical design that matters: system integration is centred on
effective communication between the actuator and the host system and suppliers'
ability to ensure this capability is increasingly important.
As a global supplier of electric actuators with a strong reputation for providing
comprehensive integration support, AUMA is well placed to comment on
actuation advancements.
Werner Laengin, senior product manager for Fieldbus Systems at AUMA, says:
"Power stations tend to be in service for up to 50 years. Technology needs to be
available as a long-term solution. We recommend using only standardised
solutions, as these are supported by a vast number of vendors worldwide."
He explains: "We always take into account standardised fieldbus protocols and
DCS integrations that ensure inter-operability with field devices. Standardised
solutions use fieldbus protocols such as PROFIBUS, DeviceNet or HART. Taking
the example of the HART interface, this combines conventional 4–20 mA wiring
with additional digital communication, which makes it possible to have a
combination of conventional wiring with digital communications."
He cites the advantages of standardised systems. "Operators can use and mix
different suppliers' devices; operational expertise can be found throughout the
world and communications protocols ensure interoperability with other devices."
advancements include a large programmable colour display
torik
Comprehensive testing
Ensuring that new devices are interoperable requires implementation testing to
ensure they meet specifications before submission for registration. Often a
dedicated DCS integration is added to the control system. For example, the
standardised EDDL (Electronic Device Description Language) is one method
used to describe a unit's parameters and minimum and maximum values for
diagnosis of a field device.
An EDD is basically an ASCII text file which can be read by an EDDL interpreter
which then presents the field device diagnosis or parameter information on the
central maintenance screen.
Laengin reflects on the process required to ensure harmony in configurations
within the DCS system and the field devices.
"The current interpretation of EDDL language varies slightly between different
interpreters. Therefore we tend to recommend dedicated integration tests in
order to ensure that once things come together, there is flawless device
integration. Flawless device integration of each and every parameter, of each
and every menu, of each and every maintenance and diagnostic information is
essential in order to ensure there is no issue when it comes to commissioning."
With increasing amounts of intelligence included in field devices, DCS integration
is a fast moving field.
Laengin is excited by the possibilities. "Smart actuators can trigger alarms on
minimum or maximum readings. Increasing intelligence means they can also
interpret their own history.
"They not only count the number of switch offs or the number of open and close
cycles, they are also able to record the environmental conditions, the torque
applied to the valve and are able to make interpretation of availability for the
future. They can make an indication about which kind of maintenance has to be
done at which time for the specific application."
Maintaining continuity
The operational life of a power station can be measured in decades, with thermal
and nuclear stations remaining in production for as many as 50 years. Operators
are keen to extend the life of existing thermal and nuclear stations where this is
feasible.
Rapid developments in electronics have driven advances in control systems and
state-of-the-art actuator/valve combinations are now installed in new plants.
However it may not be appropriate to retrofit these devices to an established
plant. A lot of the control systems in older power stations may not be suited to
modern electronic systems and the best course of action might be to overhaul
and refurbish the original electro/mechanical valve actuators to maintain plant
continuity.
Weir Engineering Services actuator workshop in Alloa, Scotland, is an
engineering centre of excellence that provides services to the power generation
sector, including the refurbishment and upgrade of valve actuators which may
have been in operation for decades.
Workshop supervisor Phil Russell explains: "We see many actuators which were
originally supplied in the mid 1960s and have been in service ever since. During
40 odd years of operation some have already taken advantage of overhaul and
service exchange programmes, some have been partially maintained, and others
may not have been maintained at all."
Electro/mechanical actuators consist of a gearbox with an electric motor and
electrical switchgear. Such actuators were often supplied to power stations with a
design life of 25-30 years as 'fit and forget' items. Soft parts such as oil seals and
O rings had a useable shelf life of between 10 and 15 years but in many cases
there were no recommended service intervals for the actuator. Weir is confident
that a major overhaul meets the aspirations of any life extension programme by
returning the actuator to the customer in an "as new" operational condition.
Operators of the older nuclear fleet have a general understanding that remaining
with the original design intent is less problematic than retrofitting an equivalent
because design and engineering change is not required and controls and HMI
interfaces are not compromised.
When comparing the cost of overhauling an existing unit with the supply and
retrofitting of an equivalent unit of different design, the apparent cost benefit of
the new unit is often outweighed by the cost of the technical justification,
installation and plant control system alterations.
Phil Russell sees a great opportunity for re-energising old installed product rather
than replacing with a different design."A WES workshop refurbishment involves a
full strip down, evaluation of any damaged or obsolete components, upgrade to
the current design specification, rebuild and test. As much of the original
electrical equipment is now obsolete, we will either perform a complete re-wire
and fit all new electric components or leave the wiring looms intact and just fit
new electrics."
A power station may have hundreds of electric actuators installed. Russell says
in a traditional power station this is made up of four or five main different types,
each with any number of sub types, amounting to 30-40 different actuators with
minimal differences.
"One way we have been looking at keeping up with reduced customer outage
times is by offering service exchange programmes. A pool of new, spare or
reclaimed actuators is available. We don't need to keep 30 different spare
actuators in stock as the appropriate model can be easily selected from a smaller
pool and configured for a specific application to fit a plant where a requirement
has been identified.
 "The actuator(s) can be prepared ahead of an outage or maintenance window
which means that instead of removing a faulty actuator and trying to fix and
replace it in a tight time-frame, the unit can simply be exchanged which may take
as little as two to three hours. The unit that comes off is returned to us for
refurbishment and then goes back into the pool of spare actuators in preparation
for future use."

which have been in service since the 1960s," says Weir's Phil Russell (right)
neering Services
Keeping pace with technology
The basic design of valves and mechanical actuators is established, but as
power plant technology moves forward, devices must be designed to operate
more accurately, more flexibly and under central rather than local control.
Devices must operate with precision and speed in the increased temperatures
and pressures found in big modern plants.
Actuators and valves are an essential and established component in power
plants. As power plants evolves to operate with greater flexibility and efficiency,
developments in electronics will play a key role in enabling state of the art
actuators to keep pace.