Digital Control System of Plant Gyanendra Sharma NPTI Delhi

DDCMIS
(DIGITAL DISTRIBUTED
CONTROLS AND MANAMAGEMENT INFORMATION
SYSTEMS)
Saturday, March 27, 2021 Gyanendra Sharma - NPTI Delhi 1

Presentation Layout
• TECHNOLOGICAL PROGRESS and evolution

• Over view of DAS
• Function and Component of DAS
• Salient features and major componenets
of DDCMIS
• Overview of MAXDNA

TECHNOLOGICAL PROGRESS
CONTROL AREA
• LOCAL CONTROLS
• CENTRALISED
• FUNCTIONALLY DISTRIBUTED
• MORE AND MORE GEOGRAPHICALLY DISTRIBUTED

EVOLUTION OF DDCMIS
• ORIGINALLY MEASUREMENT WERE MOST IMPORTANT (MEASUREMENT + HUMAN

REACTION + MANUAL CONTROL)
• OPEN LOOP CONTROL (HARDWIRED-Relay Based )
• OPEN LOOP CONTROL (HARDWIRED-Solid SATE )
• CLOSED LOOP CONTROLS (HARDWIRED-Analog SYSTEM )
• COMPUTERISED DAS
• INTEGRATED DDCMIS

Development of Process Control
Early control of processes
Beginning of Local control room

More advanced control Rooms
Computer ANALOG PANEL Process

• This central control concept give better picture of over all
plant operation ,but when distant portion of the plant
connected of the plant to one room the cost of following will
be very high
• Cable tray and cable
• Engineering design
• Labor for installing
• Problem in changing strategy

Analog system as back up
Analog Back up
Computer
Process

CONTROL & INSTRUMENTATION
Centralized Control room with back

up analog panels and DAS system
Choices of open network flexibility
Work Station
as HMI /PC
Controller Controller Controller Controller
User choice Single Distributed Control Strategy

Upload Control Single configuration
Data base for: Each Controller stores its own
Screen view Configuration
Trends Documentation
History Tag name and HMI CALL
Peer to peer network links for complex strategy
Bridge software to populate HMI Database

MIS SYSTEM /
DATA ACQUISITION SYSTEM
Overview of DAS
• What is DAS
• Need/purpose for DAS
• Function of DAS
• Features in DAS

WHAT IS DAS
• Computerised intelligent system presenting
data from the entire plant in desired and on as
required basis to facilitate easy monitoring,
recording and to enable operator to take quick
decisions regarding operation.

NEED FOR A DAS
• To collect process and present field data to operation and
management
• For Efficient operation of Power Plant, close monitoring of
various plant equipment and their parameters is required.
• Indicating each of such parameters separately in control room
requires lot of space.
• DAS will solve many of the problems by displaying lot of
analog as well as Digital points simultaneously in one Monitor.
• To collect process and present field data to operation and
management

FUNCTIONS OF DAS
• Displaying all the DATA in a systematic format, so that the data
can be used by the operator in a efficient way.
• Giving the operator alarms, in case of any deviation of
parameters from the normal range.
• Storage of DATA for retrieval at a later date.
• Generation of LOGs, for monitoring the parameters and
improving the efficiency.
• Generation of SOEs for analysing the cause of unit Tripping/
any emergency etc.

Functions of DAS
• Measurement
• Analog, Binary and Pulse Signal Conditioning
• Data Display
• Alarm monitoring and Printing

Functions of DAS (contd.)
• Logging
- Daily Logs
- Sequence of Events Log
- Post Trip Log
- Boiler Start-up & Shut-down Log

Functions of DAS (contd.)
• Historical Storage
• Performance Calculations
- Heat rate of Boiler , Turbine ,
Unit etc.
• Diagnostics

SOE
• A max of 256 important digital input points
• 1 Milli Second Resolution
• Prints after 3 min. of last digital change
• Later modified as 5 min. data

Back

Post Trip Log
• 300 Important Analog Points
• Collected for 5min. Before and After TRIP
• 10 Sec. Resolution
• Circular Buffer
Back

Historical Storage
• Plant data , alarms , SOEs , Post trip logs
• Previous Two Days Data on Hard Disk
• 15 Days Data on Magnetic Tape
• Latest Stage I : 60 days data on Servers

Back

DATA DISPLAY
• Video Trend
• Bar Charts
• Mimics / Graphics
• Periodic Display
Back

FEATURES IN DAS
• Group review displays
• Graphic mimics
• Bar charts
• Alarm Displays
• Historical Storage
• Real Time Trends
• Operator Guidance Messages
• Logs

GROUP REVIEW
• Used for Displaying DATA in a group.
– All the DATA relating to a particular Auxiliary
– DATA relating to a System (Feed water etc)

GRAPHIC MIMICS
• Displaying the DATA on the Plant mimics
– Better understanding of the Process

ALARM DISPLAY
• Displays all the alarms in the order of their
occurrence
– Useful for analysing the cause of the major
failures.
– All digital DATA and Analog values crossing the
limits will be displayed in this window in the order
of their occurrence.

HISTORICAL STORAGE
• All important DATA can be stored in the
Storage Devises available and can be retrieved
later for analysis.
– SOEs
– LOGs

REAL TIME TREND
• Operator can configure the required points for
real time trending purpose and can see the
real time trend and in case of any deviation
(abnormal change) can react quickly.

OPERATOR GUIDANCE MESSAGES
• Operator Guidance messages can be displayed
on the DAS monitors when rolling or any
important activity is going on.

LOGS
• Event Activated logs
– SOE
– Post Trip Log
– Start-Up Log
• Time Activated Logs
– Daily Log
– Shift Log
• Maintenance Data Log
• On Demand Logs

HARDWARE
• CPU
• I/O CARDS
• CRTS
• PRINTERS
• NETWORK

Typical Architecture of DAS
• There are three Controllers Units (NODES)
– Each node has 2 CPUs
– One is Primary other is Secondary
– Each controller Unit will process some I/O cards.
• 2 Nos Servers for getting DATA from CPUs and displaying in
Operator Work Stations.
• 4 Nos Operator Work Stations.
• 1 Engineering Work Station.

CONTROLLERS
• Each controller unit is connected to a set of I/O cards through Bus
• Each node contains 2 CPUs.
• One is primary other one is secondary.
• Both Primary and Secondary are connected through a High Speed Link.
• Program in Controller is divided into 3 parts
– Firm Ware
– Operating System
– User Defined Configuration
• Any configuration change has to be stored in both the controllers.
• Controller will send the data to Servers via AF100 Bus

SERVERS
• Servers will get data from the Controllers via
AF100 Bus and puts the DATA on Ethernet for
access to other workstations.
• It stores all the historical data.
• It stores all the configuration DATA.
• MOD drives are used for taking the DATA
Backup (600 MB)

ENGINEERING WORK STATION
• Engineering workstation is used to do the configuration
changes in the Controllers and loading the OS when new
controller is to be installed.
– Any new points to be configured
– Change in Ranges
– Doing some calculation in Controllers
• Configuration
– Database Part
– PC program

OPERATING SYSTEM
• All Operator Work Stations, Servers,
Engineering work station runs on Windows
2000 OS.

ADVANTAGES OF DAS SYSTEM
• Mostly DAS were basically a DCS.
• This can be used for control purpose also.
• All three units are connected through a
network and DATA can sent to CC.
• It has facilities such as DDE and OPC for
sending DATA to other applications.
• Intelligent alarm system.
• Performance Calculations

SALIENT FEATURES AND
MAJOR COMPONENTS OF
DDCMIS

SALIENT FEATURES OF DDCMIS
• INTEGRATED PLANT CONTROL FOR SG, TG AND

BALANCE OF PLANT CONTROL IT
• MAY BE REMEMBERED THAT HISTORICALLY THE TERM DDCMIS

USED TO BE REFERRED FOR THE SO-CALLED “BOP-C&I” . THE SG-
C&I, i.e. FSSS etc. TG-C&I i.e. ATRS, TURBINE PROTECTION etc.
ORIGINALLY WERE NOT CONSIDERED UNDER DDCMIS OR DCS AS
PER MANY SUPPLIERS. ONLY RECENTLY THE TYPE OF SYSTEMS FOR
ALL THE SYSTEMS HAVE BECOME SIMILAR (WITH SOME
DIFFERENCE WHICH WILL BE DISCUSSED LATER),.

SALIENT FEATURES OF
DDCMIS
• INTEGRATED PLANT OPERATION THROUGH FULLY

INTERCHANGEABLE OPERTAOR WORK STATIONS (OWS) FOR
SG, TG AND BALANCE OF PLANT (SOMETIMES THIS
MAY NOT BE POSSIBLE DUE TO PACKAGING CONCEPT)

• PROVISION OF EXTENSIVE SELF-DIAGNOSTICS

• USE OF LARGE VIDEO SCREENS FOR PROJECTIONS OF
VARIOUS PLANT MIMICS ETC.
• PROVISION OF FAULT ALARM ANALYSIS TO GUIDE THE
OPERATOR TO THE MOST LIKELY EVENT
• PROVISION OF TREND ALARMS

• PROVISION OF SAFETY HARDWARE FOR BURNER

MANAGEMENT SYSTEMS
• PROVISION OF FAIL-SAFE HARDWARE FOR TURBINE

PROTECTION SYSTEM
• PROVISION OF ADEQUATE RELIABILITY AND

AVAILABILITY WITH PROPER REDUNDANCY IN SENSOR,
I/O AND CONTROLLER.

DDCMIS CONFIGURATION
maxDNA
SYSTEM
ENGG. STN
HMI
FOR HMI
PROCONTROL MMI LAN

SYSTEM
HMI
REDUNDANT
SERVERS
ENGG.STN.
FOR CONTROL SYS. I.P. BUS Max. 4
nos. rdundant
Redundant
F.G.Controllers
Measurement system / I/O

subsystem

MAJOR COMPONENTS OF
DDCMIS

MAJOR COMPONENTS OF DDCMIS
• CONTROL SYSTEM
• MAN-MACHINE INFORMATION AND PLANT INFORMATION

SYSTEM (MMIPIS)
• REDUNDANT DATA COMMUNICATION SYSTEM (DCS)

MAJOR COMPONENTS OF DDCMIS
• SEQUENCE OF EVENT (SOE ) AND ANNUNCIATION SYSTEM

FUNCTIONS
• SYSTEM PROGRAMMING FACILITY

a) TUNING & CONFIGURATION FOR CONTROL SYSTEM
b) MODIFICATION & PROGRAM DEVELOPMENT FOR MMIPIS
• MASTER & SLAVE CLOCK SYSTEM

CONTROL SYSTEM

CONTROL SYSTEM
PROGRAMMING & MMIPIS M&S
CONFIGURATION SYSTEM CLOCK
DCS
SG- C&I BOP- C&I TG- C&I

SYSTEM SYSTEM SYSTEM

SG-C&I SYSTEM
• CONSISTS OF BURNER MANAGEMENT SYSTEM
(BMS), SOOT BLOWER CONTROL SYSTEM (SBC),
SECONDARY AIR DAMPER CONTROL SYSTEM
(SADC), AUXILIARY PRDS CONTROLS (APRDS)
• FOR BMS, “SAFETY SYSTEM” HARDWARE IS
SPECIFIED, i.e. THE HARDWARE , WHICH MEETS
THE REQUIREMENT OF RELEVANT NFPA AND
VDE STANDARDS`

SG-C&I SYSTEM
• TRIPLE REDUNDANT CONFIGURATION FOR THE FURNACE

PROTECTION (MFT) PORTION OF BURNER MANAGEMENT
SYSTEM (BMS)
• FOR SBC, SADC, APRDS,MILL & OIL ELEV. SEQUENCE, INTERLOCK
AND PROTECTION, CONFIGURATION SIMILAR TO OLCS/CLCS
(DESCRIBED LATER)
• FOR MILL & OIL ELEV. LOGICS, SAFETY SYSTEM HARDWARE
SHALL BE USED

TG-C&I SYSTEM
• CONSISTS OF TURBINE PROTECTION SYSTEM

(TPS), AUTOMATIC TURBINE RUN-UP SYSTEM
(ATRS), AUTOMATIC TURBINE TESTING SYSTEM
(ATT), ELECTRO- HYDRAULIC TURBINE CONTROL
SYSTEM (EHTC) FOR MAIN & BFP TURBINE,
TURBINE STRESS CONTROL SYSTEM (TSCS),
GLAND STEAM PRESSURE CONTROL GENERATOR
SEAL OIL, PRIMARY WATER & HYDROGEN
CONTROL SYSTEM (RECENT ADDITION).
TG-C&I SYSTEM
• TRIPLE REDUNDANT OR 2 X 100 % REPEATED

TWICE CONFIGURATION FOR THE TURBINE
PROTECTION SYSTEM (TPS). FOR THIS, SAFETY
SYSTEM HARDWARE / FAIL-SAFE HARDWARE
SHALL BE USED
• FOR OTHERS, CONFIGURATION SIMILAR TO
OLCS/CLCS (DESCRIBED LATER) TO BE USED

BOP-C&I SYSTEM
• CONSISTS OF OPEN LOOP CONTROL SYSTEM (OLCS) AND

CLOSED LOOP CONTROL SYSTEM (CLCS)
• OLCS -THE SEQUENCE CONTROL, INTERLOCK OF OF ALL THE

PLANT SYSTEMS WHICH ARE NOT COVERED IN THE SG-C&I AND
TG-C&I. THIS INCLUDES MAJOR AUXILIARIES LIKE FD/ID/PA FANS,
AIR-PREHEATER, BFP/CEP/CWP/ BCWP , DMCWP/CLCWP AND
ELECTRICAL BREAKERS.

BOP-C&I SYSTEM
• (CLCS) -THE MODULATING CONTROL FOR VARIOUS IMPORTANT

PLANT PARAMETERS, LIKE FW FLOW (DRUM LEVEL), FURNACE
DRAFT, COMBUSTION CONTROL (FUEL FLOW AND AIR FLOW), PA
HDR PRESSURE CONTROL, DEAERATOR/HOTWELL/HEATER LEVEL
CONTROLS ETC.

MMIPIS

MAN-MACHINE INTERFACE AND PLANT
INFORMATION SYSTEM
• LATEST STATE-OF-THE-ART WORKSTATIONS /PCs AND SERVERS

BASED ON OPEN-ARCHITECTURE AND INDUSTRY STANDARD
HARDWARE AND SOFTWARE TO ENSURE BETTER CONNECTIVITY.
• e.g. HARDWARE FROM COMPAQ/DIGITAL, HP, SUN MICRO-SYSTEM
OR OTHER MAJOR SUPPLIERS (LESS DEPENDENCE ON THE C&I
SYSTEM SUPPLIER IN THE LONG RUN)
• OPERATING SYSTEM WINDOWS-2000, OPEN-VMS OR UNIX.

MAN-MACHINE INTERFACE AND PLANT
INFORMATION SYSTEM
• 64/ 32-BIT SERVER/OWS WITH HIGH-SPEED AND LARGE
MEMORY (256/512 MB RAM, 8 GB HDD FOR SERVER AND
128/256 MB RAM AND 4/6 GB HDD FOR OWS) TO ENSURE
FAST RESPONSE
• PROVISION OF LVS
• CONNECTION TO OTHER SYSTEM THROUGH STATIONWIDE
WAN

MMIPIS FUNCTIONALITIES
• VPC OPERATION
• OTHER OPERATOR INFORMATIONS THROUGH
VARIOUS DISPLAYS
• ALARMS, LOGS, HISTORICAL AND LONG TERM
STORAGE.
• PERFORMANCE AND OTHER CALCULATIONS

OPC Solves the Problem
Display Trend Report
Application Application Application
OPC OPC OPC
OPC OPC OPC OPC

Software Software Software Software
Driver Driver Driver Driver

SOE

• SEQUENCE OF EVENT (SOE ) AND ANNUNCIATION SYSTEM
FUNCTIONS
• ORIGINALLY THESE USED TO BE STAND-ALONE SYSTEM (DIODE

AUCTIONEERING, DBTC ETC REQUIRED)
• NOW INTEGRATED -THEREFORE THE DIODE AUCTIONEERING,
DBTC ETC NOT REQUIRED
• SOE - 1mS RESOLUTION, STORAGE OF REPOTRS FOR LONG
DURATION
• ANNUNCIATION LOGIC THROUGH OLCS/CLCS CONTROLLERS.

SYSTEM
PROGRAMMING
FACILITY

SYSTEM PROGRAMMING FACILITY
• LATEST TREND - COMBINED CONTROL SYSTEM

TUNING & MMIPIS PROGRAMMING
• SELF-DOCUMENTATION
• ENGINEERING WORKSTATIONS

Object-Oriented Configuration
• Graphical object-oriented
configuration software tool
• Includes self-documentation of
configuration
• True object-oriented features
including encapsulation and
inheritance
• Library of standard algorithms
or “objects”

C
MASTER & SLAVE
CLOCK SYSTEM

MASTER & SLAVE CLOCK SYSTEM
• RECEIVES TIME SYNCHRONISATION SIGNALS

EITHER FROM THE GEO-POSITIONARY SATELITE
(NPL SIGNAL)
• DISTRIBUTES THIS SIGNAL TO THE MMIPIS AND

THE CONTROL SYSTEM.

OTHER RELATED TOPICS

• POWER SUPPLY SYSTEM
• CABLING & TERMINATION OTHER SG/TG C&I

SYSTEM/ EQUIPMENT
• PACKAGING CONCEPTS- SCOPE OF SUPPLY OF
C&I SYSTEM/PACKAGE

• OPERATION PHILOSOPHY , CONTROL AREA AND

BACK-UP INSTRUMENTATION & GEOGRAPHICAL
DISTRIBUTION - COMBINED CYCLE PLANTS
• REDUNDANCY
• DESIGN CRITERIA

POWER SUPPLY SYSTEM
• CONTROL SYSTEM POWER SUPPLY TWO SETS OF DC POWER SUPPLIES - ONE

SET FOR SG/TG-C&I AND OTHER FOR BOP-C&I EACH WITH 2 X 100 %
CHARGER AND 2 X 100 % BATTERY.
• OTHER IMPORTANT AC LOADS LIKE MMIPIS, PANEL INSTRUMENTS,
ANALYSERS ETC. SHALL BE POWERED FROM UPS COMPRISING OF 2 X 100 %
CHARGER, 2 X 100 % INVERTER AND 1 X 100 % BATTERY.
• HEAVY DUTY Ni-Cd BATTERIES HAVE BEEN ENVISAGED FOR LONGER LIFE &
LESSER MAINTENANCE

CABLING & TERMINATION
• EXTENSIVE GROUPING OF SIGNALS BY LARGE SCALE USE OF JBs

AT STRATEGIC LOCATIONS
• USE OF CABLES WITH HIGHER NO OF PAIRS
• USE OF CAGE-CLAMP CONNECTION FOR SYSTEM CABINETS,
MARSHALLING PANELS & OUTGOING SIDE OF JBs, CJS BOXES
etc.
• USE OF PLUG-IN SOCKET AND CONNECTORS FOR
TRANSMITTERS, SWITCHES, LS/TS etc.

IMPORTANT SG/TG RELATED C&I SYSTEM
• FLAME MONITORING SYSTEM

• COAL FEEDER C&I
• ELECTROMATIC SAFETY VALVES
• FURNACE TEMP PROBES
• ACCOUSTIC PYROMETER FOR FURNACE TEMP PROFILE
• BOILER FLAME ANALYSIS SYSTEM
• COAL BUNKER LEVEL MONITORING SYSTEM
• ELECTRONIC DRUM/SEPARATOR LEVEL MONITORING SYSTEM
• TURBINE SUPERVISORY SYSTEM
• TDBFP TURBINE SUPERVISORY SYSTEM
• IN PACKAGED SYSTEM, THESE ARE UNDER SG & TG PACKAGES.

OPERATION PHILOSOPHY
• CENTRALISED OPERATION OF MAIN PLANT THROUGH OWS & LVS

• OFF-SITE PLANTS TO BE CONTROLLED FROM THEIR LOCAL STATIONS WITH
STATION-WIDE LAN DATA LINK
• MINIMUM BACKUP INSTRUMENTATION ( ORIGINALLY CONSERVATIVE, NOW
REDUCED. CRITERIA - HANDLING EMERGENCY & SAFE SHUT-DOWN)
• GEOGRAPHICAL DISTRIBUTION - ALTHOUGH NOT VERY USEFUL FOR POWER
PLANTS AS COMPARED TO PROCESS/INDUSTRIES, BEING ADOPTED FOR FEW
AREAS WHERE SIGNALS ARE CONCENTRATED (REDUCTION OF CABLING, MUCH
LESS ERECTION & COMMISSIONING TIME)

DESIGN CRITERIA
• PROVENNESS
– SUPPLIER’S EXPERIENCE
– SYSTEM EXPERIENCE
– PROVENNESS VS OBSOLESCENCE
• RELIABILITY AVAILABILITY
– HARDWARE QUALITY (PUBLISHED MTBF etc.)
– CONFIGURATION
– REDUNDANCY
– FAULT TOLERANCE
• STANDARDISATION AND UNIFORMITY OF H/W
– SAME SERIES & FAMILY OF H/W AS FAR AS POSSIBLE
– DIFFICULTIES BECAUSE OF PACKAGING CONCEPTS & RESPOSIBILITY CENTRE &
INTERFACES (EVEN IN TURNKEY PACKAGE)

DESIGN CRITERIA
• OPERABILITY
– DESIGN CONCEPT - FAIL SAFE ETC.
– FALSE TRIP VS SAFETY
– OPERATOR CONVENIENCE DURING NORMAL RUNNING & EMERGENCY
– MANAGEMENT REPORTING
• MAINTAINBILITY
– STANDARDISATION (AS INDICATED ABOVE)
– MODULAR DESIGN AND EXPANDABILITY
– DIAGNOSTIC, FAULT IDENTIFICATION AND FAULT TOLERANCE
– GUARD AGAINST OBSOLESCENCE
– AVAILABILTY OF SPARES
• OTHER CRITERIA
– UNIT OPERATION PHILOSOPHY
– MARKET TRENDS AND EVOLUTION OF INFORMATION TECHNOLOGY
– FEEDBACKS FROM EXISTING SYSTEMS

PANELS & CARDS
BACKPLANE
DPU
Analog Input Modules
Digital Input Modules
Analog Output Modules
Digital Output Modules
Special Modules

NETWORK COMPONENTS
DPU
DCS Network A/B
MMI Network A/B
Operator Workstations
Large Video Screens
OPC, WAN

POWER SUPPLY
24 V DC
UPS -240 V AC
110 V AC
220 V DC
BACKUP PANEL

BACKPLANE
• We are using 8 wide maxPAC backplane.
• This is a printed circuit board.
• DPU & IO Cards are plugged in to this board.
• Different backplanes in a panel/suite of panels
are connected in daisy chain fashion using
ribbon cables.
• Two power supply connectors are available on
this board. One is for card supply & the other is
for field interrogation supply

Distributed Processing Unit - DPU- is the
DPU
hardware processing engine of maxDNA.
It runs under WINDOWS CE multitasking
runtime operating system.
DPU’S front panel contains status LEDS,
takeover & reset buttons.

DPU’s front chasis panel contains network (A/B),
backup & serial port connectors, mode & network
address switches, key switch.

DPU
* Performs data acquisition, data processing & Controls
* Does alarming & calculations
* Logging of SOE at 1 millisecond resolution
* Acquisition of trend information
* Continuous scanning of IO modules

* Execution of predefined algorithms

Input/Output Cards

Analog Input Module - IOP 301
Accepts Current/Voltage Inputs

16 Channels are available
Field input isolation is available
Scanning time is 100 millisecond
15 Bit + 1 sign bit Accuracy

Analog Input Module - IOP 301
Some internal details

* Analog Input Module - IOP 303
Used for 3 wire RTD inputs
One card can take 08 inputs
8 Points converted in 1.6 S
Each channel can be programmed for type
* Analog Input Module - IOP 304
Used for Thermocouple Inputs
One card can take 16 inputs
16 Points converted in 1S
Each channel can be programmed for type
* Digital Input Module - IOP 330
Process 16 Digital Inputs

* Analog Output Module - IOP 320
8 Outputs
Outputs are short circuit protected
Scan time 8 millisecond
Resolution 12 Bit

* Digital Output Module - IOP351
16 Outputs are available
Contact Rating
5 A 240 V AC
3A 30 V DC
0.3 A 110 V DC

Typical wiring scheme for IOP 350
24 V DC
Fuse
Card Field Device

1. Bus Extender Module - IOP 371
2. DSZAB module
3. Contrac EAS 822
4. PROmax Cards (Used in EHC)
Position Feedback cards
Power Amplifier cards
Position Controller cards
5. Y ADAPTOR
Bus Extender Module - IOP 371
Rack A Rack B
FOC
Rack B (mounted in a remote panel) is

now an extension on Rack A
Connects the Common IO to primary
and secondary DPUs
D
P
U
Redundant IO Y
ADAPTOR
Common IO
D
P
Ribbon
U Cable
Redundant IO
There are two sets of sources - SGTG & BOP
Each set consists of two redundant supplies
SGTG source feeds all SG & TG panels
BOP source feeds all BOP panels

BOP SOURCE
1
- DCS
~ PANEL
DCDB
2
-
~
DCDB

g
D
rin
P
wi
U
l D
ne
P
Pa
-
-
SOURCE 1 E
SOURCE 2
Panel wiring
A A A A
B B B B
C C C C
D D D D
E E E E
F F F F
G G G G
2TBA H H H H
1 2 3 4
H H H H
G G G G
F F F F
E E E E
D D D D
C C C C
B B B B
IOP 301
A A A A
Saturday, March 27, 2021

FIELD
BACK SIDE
Gyanendra Sharma - NPTI Delhi
FRONT SIDE 120
105 KVA, Emerson Network Power Make
Feeding
Workstations MDBFP SCOOP
Vibration Monitoring Panels ACCSP
SWAS, O2, SOX, NOX Analysers Seal Oil system Switches
Pulverisor Lube Oil System Switches DOZING pump panels
CRH Drain pot level swtiches
PW tank level transmitters
DCS NETWORK
D
P
U
DCS A
D WORK
MMI A
P STATION
MMI B
DCS B
NET A
NET B
Panel
Auto Manual Stations, Start / Stop Buttons,
Analog/Digital Indicators & Alarms are
provided on this panel
DPU & Backup panel instruments are

connected to each other through IO modules
Unit can be operated from this panel.

Software

Offline Tools
maxDPU Tools
maxVUE Editor
Report Editor
mxs Config

Online Tools
maxVUE Runtime
Event Collector
Event Logger
maxStorian
mxs Dial

Program Flow
Field
DPU
Input Card
To Other
Tagging DPUs &
Applications
Processing
Output Card
Field
Tagging Indication

THANK YOU

Digital Control System of Plant Gyanendra Sharma NPTI Delhi

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DDCMIS

Saturday, March 27, 2021 Gyanendra Sharma - NPTI Delhi 1

• TECHNOLOGICAL PROGRESS and evolution

Saturday, March 27, 2021 Gyanendra Sharma - NPTI Delhi 2

• MORE AND MORE GEOGRAPHICALLY DISTRIBUTED

Saturday, March 27, 2021 Gyanendra Sharma - NPTI Delhi 3

• ORIGINALLY MEASUREMENT WERE MOST IMPORTANT (MEASUREMENT + HUMAN

Saturday, March 27, 2021 Gyanendra Sharma - NPTI Delhi 4

Saturday, March 27, 2021 Gyanendra Sharma - NPTI Delhi 6

Computer ANALOG PANEL Process

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Centralized Control room with back

Controller Controller Controller Controller

User choice Single Distributed Control Strategy

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Saturday, March 27, 2021 Gyanendra Sharma - NPTI Delhi 17

• Analog, Binary and Pulse Signal Conditioning

• Alarm monitoring and Printing

Saturday, March 27, 2021 Gyanendra Sharma - NPTI Delhi 18

- Sequence of Events Log

- Post Trip Log

- Boiler Start-up & Shut-down Log

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• 1 Milli Second Resolution

• Prints after 3 min. of last digital change

• Later modified as 5 min. data

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• Collected for 5min. Before and After TRIP

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• Previous Two Days Data on Hard Disk

• 15 Days Data on Magnetic Tape

• Latest Stage I : 60 days data on Servers

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• INTEGRATED PLANT CONTROL FOR SG, TG AND

• MAY BE REMEMBERED THAT HISTORICALLY THE TERM DDCMIS

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• INTEGRATED PLANT OPERATION THROUGH FULLY

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• PROVISION OF EXTENSIVE SELF-DIAGNOSTICS

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• PROVISION OF SAFETY HARDWARE FOR BURNER