STG Process Control System - Procontrol

Date: 14/03/2012

Liji P C&I

A common misconception in process control is that it is all about the controller – that you can force a particular process response just by getting the right tuning parameters. In reality, the controller is just a partner. A process will respond to a controller’s commands only in the manner which it can. To understand process control you must understand the other partners as well: sensors, final control elements and the process itself. All of these determine what type of response the controller is capable of extracting out of the process. It is not the other way around.

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 Objectives:

      

Why do we need process control? What is a process? What is process control? What is open loop control? What is closed loop control? What are the modes of closed loop control? What are the basic elements of process control?

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4. 2. Safety Production Specifications Environmental Regulations Operational Constraints Economics Confidential Slide 4 . 3.Operational Objectives 1. 5.

N SWITCH GEAR / MOTOR CONTROL CENTER Low PROCESS Slide Confidential .HIERARCHY OF CONTROL High Unit Level DEGREE OF AUTOMATION Particular Process Function group Level SUB GROUP LEVEL Sub loop Control Sub loop Control Sub loop Control Individual Equipment and drives 1 DRIVE CONTROL LEVEL 2 3 4 5 6 7 8 …..

Components of DDCMIS MAN MACHINE INTERFACE & PROCESS INFORMATION SYSTEM DATA COMMUNICATION SYSTEM ( DATA HIGHWAY) CONTROL SYSTEM Confidential Slide 6 .

Architecture Confidential Slide 7 .

Main Characteristics   Based on serial bus architecture Modular hardware and software Confidential Slide .

C&I system  Hardware Components Confidential Slide .Components of DDCMIS  Functional Division – S&G .C&I system – BOP .C&I system – T&G .

Data Transmission   Serial bus Two levels – Local Bus P13 – Intraplant bus P42 Confidential Slide .

Process control System Confidential Slide 11 .

Local Bus   Heart of the station and connects to all modules in the station Features  Transmission reliability – Parity check. clock signal     Redundancy Time cycle : 40ms Type of modulation : Pulse modulation No of addresses : 256 Confidential Slide 12 . data valency . cyclic transmission.

Local Bus.  Local bus structure  Seven lines – – – – – – – AD : Address DN : Data / information DI : Inverted Data / information CK : Clock US : 24 VDC power supply ZD : for reference conductor for bus signal Z : for reference conductor Confidential Slide 13 ..

. Confidential Slide 14 .Local Bus.

.Local Bus. Confidential Slide 15 .

Local Bus.. Confidential Slide 16 .

Amplitude tolerance check .Redundancy      Time cycle : 40ms Type of modulation : Digital Pulse Width modulation No of addresses : 256 x No of stations (63) Amplitude: 15 v Transmission medium: Coaxial cable Confidential Slide 17 . process computer with diagnostic station with redundant line Features  Transmission reliability – Parity check.Intra plant Bus   Link all station with local bus.

.Intra plant Bus. Confidential Slide 18 .

Intra plant Bus. Confidential Slide 19 ..

Confidential Slide 20 .Intra plant Bus..

.Intra plant Bus. Confidential Slide 21 .

. Type BV01 FA01 Application Local bus traffic director Description transfer of data signals into the IPB cable and for transfer of address and data signals from the IPB cable in to local bus stations Contains FA01 modules FK01 Confidential Slide 22 .Intra Plant Bus.

Confidential Slide 23 .Intra plant Bus..

PROCONTROL H/W LIBRARY INPUT MODULES OUTPUT MODULES CONTROLLER MODULES INTERFACE . FA01 . BV01 . XV7713 ANALOG . EB02 . EB03 . BK02 . EA04 BINARY . AS06 BINARY . BA01 ANALOG . XV7718 . DIR’S . BV05 . EA02 . XV7717 .AB01 . EA03 . AA02 BINARY .AS04 DRIVE MODULES . PR05 .AB02 TRA . AA01 . BK03 . PR03 . XT382 . EB01 . XV7715 PROC’S . FV01 POWER SUPPLY . XT383 .XT370 Confidential Slide . EA01 . EB10 ANALOG .

supervise and protect one FCE With microprocessor and I/Os Can be interfaced with serial bus Additional and optinal capability to interface FCE with control operatr room via h/w – Fault tolerant system – redundancy element Confidential Slide .Control Modules  Two basic type of modules – Individual control modules – Universal control modules  Individual control modules – – – – Implemented to control.

Control Module.. Confidential Slide 26 .

. Confidential Slide 27 .Control Module.

Redundant Communication via local bus Confidential Slide .

CLOCK ADDRESS BV 2 F 0 3 BA DATA DATA 1 A 3 F 2 A EB EA AA AB PR ACTUAL VALUE ORDER ORDER Confidential Slide .

.Processor Module. Type PR05 Application Description 4 channel 2 code sw for address setting 4 channel 2 code sw for address setting Short circuit proof supply to contacts Confidential Slide 30 .

sign.disturbance Address allocation Serial/Pareellel Conversion - Confidential Slide . Zero/Span Digitalization – 10 bit data.IO Modules    Mounted on local bus Both normal and reverse data Functions – Power to transmitter/switches Signal Veriication – power.

Address allocation  Via code switches Confidential Slide .

IO Modules       Power for transmitters and transducers Signal verification Digitalization Address allocation Serial / Parallel conversation Process interface Confidential Slide .

24vDC supply for txr.I/O Modules.* Slide 34 EA02 4 – 20 mA EA03 Temperature measurement EA04 Temperature measurement Confidential .10 VDC Description 4 channel 2 code sw for address setting Selection of input via jumpers.* RTD(Pt 100) 4 channel 2 code sw for address setting Linearisation for measurement..  Analog Input modules Type EA01 Application 0 .* Thermoelectric voltages Correction with coldjunction temperture 8 channel 2 code sw for address setting Linearisation for measurement.* 4 channel 2 code sw for address setting 16.20 mA or 0 .

 Binary Input modules Type EB01 Application 24vdc binary signal Conversion of 0/24v to local bus signal Interrogation voltage of 48vdc Conversion of 0/24v to local bus signal Module for supervised contact Five double throw contact No effect on earth fault Description 16 channel 2 code sw for address setting 16 channel 2 code sw for address setting Short circuit proof supply to contacts 5 channel 2 code sw for address setting Linearisation for measurement Short circuit proof supply to contacts * EB02 EB03 Confidential Slide 35 ..I/O Modules.

I/O Modules..  Analog Output modules Type AA01 AA02 Application Voltages 10Vdc For 0.20 mA Description 4 channel 2 code sw for address setting 4 channel 2 code sw for address setting Short circuit proof supply to contacts Confidential Slide 36 .

I/O Modules.  Binary Output modules Type AB01 AB02 Application Description 16 channel 2 code sw for address setting Interrogation voltage of 48vdc Conversion of digital local bus signal into output with potential free contacts 16 channel 2 code sw for address setting Confidential Slide 37 ..

SOFTWARE  Programming Language– Procontrol P10 Basic Functions Time functions Multi functions Functional blocks – for processor -  Documented with – Progress 2 – Functional diagrams Confidential Slide .

MMI

Confidential

Slide

WSPOSE
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Client server architecture Residing on P42 bus Engineering station and operator ws WSPOSE panel  VME(Versa module Europa) Cage – CPU and interface cards  Signal conditioning ,processing and filtering

Confidential

Slide

VME Cage
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2 way communication b/w server and IPB redundant RT20 CPU  Compatible with VME bus GBNIC  Ethernet controller  RT20 CPU (bnc ) and server PCIF

Confidential

Slide

Continuous flashing in healthy conditions.Off during healthy condition Confidential Slide .5A. -12V DC @200MA RT 20 has 6 front panel LEDs.       CPU RT20 is designed using Motorola M68020 microprocessor . OFF in healthy condition. BLO(RED) is illuminated when Battery voltage is low. +12 VDC @200 MA.AP2 (GREEN YELLOW) -User application LEDs .Power Rewuirement : +5VDC @2.When halt condition initiated from process. VME ( YELLOW) – Illuminated when RT20 acesses any resources.OFF during healthy condition AP1. RUN – Illuminated Green always on during running HALT.

NORMALLY OFF Confidential Slide . CONTINOUS FLASHING IN HEALTHY CONDITION STATUS LED 1 &2 GLOWS WHEN PROCESSOR HALTS AT ANY TIME. OFF DURING HEALTHY CONDITION SYS FAIL INDICATION – DURING SYSTEM FAILURE .2 SEPARATE ETHERNET CABLE IS CONNECTED TO SERVER 1 &2 .GBINC     COMMUNICATION MODULE . Rx/Tx( RED) – ILLUMINATES WHEN RECEIVES OR SEND DATA.

PCIF (Processor Control Interface Controller) interfaces VME bus and P42 bus controller The 70CK01 Module connects P42 bus and PCIF.The modules PCIF and 70CK01 are interconnected. Each PCIF acts as a local station on IPB.PCIF & 70CK01 MODULE      Function: Data Processing and broadcast the process data on ehthernet to MMI and send them on P42 P42 Bus is a coaxial cable connected to acess coupler FA.This acess coupler is connector in Buscoupler . 70CK01 is connected to coupler FA01 of Intraplant bus by means of two 8 line connecting cables Slide  Confidential .

Lone active : This will come when one server is active or communication between the servers are lost.frequency and status of server indicated in the window. Lone active Server status is indicated as – Active .The user name. Yellow : server 2 active Red :.Standby . The address selection mis made through PCIF. MW. Confidential Slide . Green : Server 1 Active.IPB COMMUNICATION CHECK       Small window in the top right corner of OPTASK indicate the status. WSPOSE System will act as two local stations in the IPB with 02 and 03 as address.

REDUNDANCY LOGIC      Failure of one server.operator station will not affect operation. In the Procontrol system ID signals are OR’ed for final controls. Failure of one work station will not affect the other system.Standby server accepts all data from Active server and operator workstations. Both servers exchange messages in every 500ms. Control commands can be issued through FKB or mouse . When there is a break the other server will take up.Active server collects data from IPB and transmits the same to operator work station and LAN. Each work station is operating separately . Standby server collects data from IPB but refrain from sending it to LAN.Any drive can be operated from any workstation . Server will go bad if communication failures from the VME or any data transfer error from IPB. Both servers operate in parallel.hence control operations proceed unhindered even if one server fails Slide Confidential . network link.

P5. J1 connector is the serial portion and P4. Each one has 4 connectors at the back.Serial Portion is connected to serial port of OWS . Each FKB.FUNCTIONAL KEY BOARD  5 numbers of FKB are available to receive signals from the OWS to WSPOSE systems. Confidential Slide .P6 connectors are parallel portion of FKB.One end of 32 Pair cable with D-37Pin connector is connected to FKB port and EB01 modules of the Procontrol Panel.

Confidential Slide ..Thank You.

APPENDIX Confidential Slide .

000 Mbit/s (depending on version) Max. devices :127 Protocol :Serial Confidential Slide . NEC and Nortel Designed :1994 Manufacturer: Intel. Intel. DEC. voltage: 5 V(±5%) Max. defined by specifications Width: 1 bit Bitrate : 1.5/12/480/5. This is in contrast to parallel communication. where several bits are sent as a whole. Compaq. IBM. Microsoft. sequentially.Serial Communication         Serial Communication is the process of sending data one bit at a time. Microsoft. over a communication channel or computer bus. IBM. on a link with several parallel channels Designer :Compaq. Nortel Signal : 5 volt DC Max. NEC. Digital Equipment Corporation. current :500–900 mA @ 5 V (depending on version) Data signal: Packet data.

or network traffic (network servers ). devices. Clients are PCs or workstations on which users run applications.Client server architecture      Servers are powerful computers or processes dedicated to managing disk drives (file servers). and even processing power. Clients rely on servers for resources. printers (print servers). decreased workflow interruptions Centralized data storage and shared resources Centralized Backup Confidential Slide . such as files. File and Network security Increased reliability.

originally developed by Motorola Confidential Slide .VME Bus  computer bus standard.

Thank you Confidential Slide .

PROTECTIONS AND LOGICS Confidential Slide .

TURBINE PROTECTION The turbine Protection System can be actuated by any of the following trip system. Hydraulic Trip System Electrical Trip System Both the trip system when initiated act on the hydraulic control system and cause trip oil pressure to collapse which in turn closes the emergency stop valves & control valves Confidential Slide .

Sequence of events when turbine trips When the turbine trips. A pressure switch sensing the low pressure condition of the hydraulic fluid or limit switches sensing the closed position of the stop valves is usually used as a verification that the turbine has tripped. Confidential Slide . the turbine control system immediately dumps the Hydraulic fluid from the main stop valves actuators and closes the stop valves.

TURBINE TRIP All HRSG Trip Emergency turbine trip Turbine speed >3300 rpm Metal temp very high >1 Turbine Trip CMD HP Steam temp low trip B C Confidential Slide .

TURBINE TRIP Axial Displacement Axial Displacement >1 Axial Displaceme nt Very High Shaft Vibration Very High >1 GCB closed Gen class A trip & >1 B Gen class B trip Confidential Slide .

TURBINE TRIP Trip oil Pressure Very Low Lube Oil Pressure Very Low MOT Level Turb Exht Pr Very High 2/3 Logic 2/3 Logic 2/3 Logic 2/3 Logic >1 C Control oil Pressure Very Low 2/3 Logic HP Steam Pr Very High 2/3 Logic Confidential Slide .

Metal Temp V High GEN FJB Temp GEN RJB Temp Turbine TB Active Turbine TB Non Active Turbine FJB Temp Turbine TB Active Turbine TB Non Active Turbine RJB Temp >1 Metal Temp V High > 115 DEG C Confidential Slide .

Shaft vibration high GEN rear shaft vibration Turbine rear shaft vibration >1 SHAFT V V.HIGH Turbine front shaft vibration GEN rear shaft vibration GEN front shaft vibration GEN front shaft vibration Turbine rear shaft vibration Turbine front shaft vibration GEN front brg vibration GEN rear brg vibration Turbine front brg vibration Turbine rear brg vibration >1 SHAFT V V.HIGH >1 Confidential Slide .HIGH Shaft Vibration Very High >1 HOUSING V V.

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