advanced control systems for esp 3

Presentation on Presentation on Advancements in ESP Control Advancements in ESP Control

SystemSystem

04/08/23 Copyright 2006 BHEL, Ranipet 2

R&D CenterR&D Center

Evolution of ESP controllers Evolution of ESP controllers in BHELin BHEL


ESP HVR CONTROL

ANALOG CONTROLLER AICE - C

RAPPING CONTROL

SYNCHRONOUS PROGRAMMER

AUTORAPPER

P BASED RAPPER CONTROLLER

MANUAL CONTROL COMPUTER CONTROLLEDPRECIPITATOR OPERATION

ESP CONTROL

BAPCON

RAPCON

IOS

High Voltage Rectifier High Voltage Rectifier ControllersControllers


Basic factors affecting ESP performanceBasic factors affecting ESP performance

Properties of Flyash - Particle size distribution -small particles are difficult to collect - surface area affects visibility, space charge


+

+

+

+

+

+BACK CORONA

qs

x i

+ ++ +

-------

EP Qs E p

F = Qs . Eav Ep . Eav Vp . Vav


Modified Intermittent ChargingModified Intermittent Charging

Increases the base voltage More suited for high charge ratio operation suitable for high resistivity dust

Outlet emission Power consumption (mg/Nm^3) (kW)

Conventional charging 351 300

Intermittent charging 127 57


Energy SavingEnergy Saving

Reduction in energy costs due to modified intermittent charging

210 MW ESPReduction in power : 243 kWAt 2 Rs./kWH and 65% duty, yearly saving : Rs. 27.7 Lakhs


BAPCONBAPCON

BHEL’s Advanced Precipitator CONtroller (BAPCON)

Highly reliable Displays in % Local & Remote

operation CR mode Warning & TRIP Alarms


Schematics of BAPCONSchematics of BAPCON

Feedback control system IP65 packing


BAPCONBAPCON

• Intermittent charging, requirement of wide charge ratio (CR) range of 1:159.

• Optimiser logic for C.R, avoids tedious manual tunning.

• Base charging, increases base voltage.• Peak & valley KV measurement : Diagnostic &

tunning facilitated.


VARIOUS DISPLAYS IN BAPCONVARIOUS DISPLAYS IN BAPCON

- Precipitator currentE Precipitator voltage H Sparks per minuteO Im limit1 Is limit2 S control3 Time control4 Stabilization time5 U.V. Limit6 C.R.7 Pulse current limit8 Repeat time9 Address Peak & valley voltageP Base chargeL Base charge current


ALARMS IN BAPCONALARMS IN BAPCONo TRIP ALARMS:

o E1 - Safety chain broken.o E2 - Eprom faulty.o E3 - Power supply failure.o E4 - Over voltageo E5 - Ash level very high (for 10 min.)o E6 - T/R temp very high / TH. Ovld.o E7 - Bucholtz bottom float.

o WARNING ALARMS:o T/R temp high.o Bucholtz top float.o Ash level high.o Under voltage.


SIGNALCONDNG

AMP.

PEAK &VALLEYDETCTR.

SIGNAL CONDNG

AMP.

SPARKDETECTOR

ANALOGTO

DIGITALCONVTR.ADC 0816)

PROGRAM(EPROM)2732 / 2764

PROCESSOR8085

OUTPUTRELAYS

PORT 1I/O

8155

SYNCH.SIGNAL

PORT 2I/O

8155

SERIALCOM.(8251)

KEYBOARD

ALARMS

FIRINGSGNL.O/P

ADDRESSSET

SPARKCOUNTER

INDICATI-NG LEDs

WATCHDOG DISPLAY

CURRET

SIGNAL

FROMTR

VOLTAGE

SIGNAL

FROMTR

SET POINT

POT. METERS.

BAPCON - DETAILED BLOCK DIAGRAM


BAPCONplusBAPCONplus

Engineering Unit display Designed for 660MW

application VFD display Local & Remote

operation CR mode Base Charge mode Warning & TRIP Alarms


BAPCON-IIBAPCON-II

Single board design Fewer components,

Higher reliability RS-485 bus based high-

speed network Remote operation Concealed in HVR panel In-built rapping


BAPCONsigmaBAPCONsigma

Primary parameters measurement

Power Measurement Open Standard

MultiMaster Network Peer to Peer

communication Spark & Arc detection and

suppression Single card design Concealed in HVR panel In-built rapping

Rapping SystemRapping System


RAPCONRAPCON

Highly Reliable platform Standalone operation Local & Remote mode

operation Real Time Clock based

motor operation Advanced algorithms

support Standby mode


ADVANCED FEATURES OF RAPCONADVANCED FEATURES OF RAPCON

Error checking for the motors. Setting of rapper timings. Setting of real time. Auto on/off selection. Manual on/off selection. Password protection. Setting of program set no. Reading of rapper times. Reading of real time. Reading of program set no. Reading of rapcon address. Reset alarm. Stan by mode selection. Communication with IOS-PC Rapping factor selection - [IOS]


PARAMETERS IN RAPCON CONTROLLED BY IOS - P.C.PARAMETERS IN RAPCON CONTROLLED BY IOS - P.C.

Rapping factor. Program set no. Auto on/off. Manual on/off. Set real time. Set rapping time. Get rapping time. Reset alarm.


COMMAND TO RAPCONCOMMAND TO RAPCON Force stand alone / standby Auto ON / OFF for all motors Manual ON / OFF for all motors Program set selection 1 - 64 Time factor 0 - 25.5 Alarm reset

REPLY FROM RAPCONREPLY FROM RAPCON Remote local Auto ON / OFF status Manual ON / OFF status Program set Time factor Alarm status Motor status Motor status 30 sec. In advance Next on status


CPU CARD( 8085 )

DISPLAY &

K.B. CARD

DATA COMMN.CARD

INPUT BUFFER

CARD

ISOLATOR

P.S.CARD

REPLY CARD

BLOCK DIAGRAM OF RAPCON BLOCK DIAGRAM OF RAPCON HARDWAREHARDWARE


BLOCK DIAGRAM OF CPU CARD OF RAPCONBLOCK DIAGRAM OF CPU CARD OF RAPCON

8254TIMER

8259PIC

8251USART

8251USART

8085

MICRO

PROCESSOR

WATCH

DOG

CIRCUIT

EPROM27128

EPROM27128

8255PPI

8255PPI

4 3 2 1

RAM6264

FEEDBACK FROM

MOTOR CONTACTS

TO MOTOR CONTACTS

DIP

SWITCH

6.144 MHz

TIMER 0TIMER 1TIMER2

IR 0IR 1

IR 7

TX

RX

TX

RX


BLOCK DIAGRAM OF DISPLAY AND KEYBOARD CARD OF BLOCK DIAGRAM OF DISPLAY AND KEYBOARD CARD OF COMCON/RAPCONCOMCON/RAPCON

8279 SWITCH

74138

74145

LEDMATRIX

9 * 8

CONNECTORFOR

KEYBOARD

ULN2003

DATA

IRO


1

345

7

2

89

10111213

6

141516171819202122232425262728293031323334

+-

RL1

RL2

RL3

RL4

RL5

RL6

RL7

RL8

RL9

RL10

RL11

RL12

RL13

RL14

RL15

RL16

RA

PPIN

G M

OT

OR

ON

CO

MM

AN

D

-+

24V

DC

TB

2/13

TB

2/10

DA

TA

CO

MM

UN

ICA

TIO

N C

AR

D

RELAYCARD

RAPPER RELAY CARD - MOTOR ON COMMAND


DISPLAYCARD

CPUCARD

POWERSUPPLY CARD

RAPCON - 1

5 6 7 8 1 2 3 4 5 6 7 8 9 10 11 12 13 14 1516 17 18

} TO INPUT CARD

TO RELA CARD

LP7

24VAC

COMM.LOOP

COMM.LOOP

TB 1

DATA COMMUNICATION CARD

P N24V DC

GND

- - - + + +

TO ANN.CKT

TXR

24V AC

TO IN

PUT

CA

RD

TO R

ELA

CA

RD

4A

K29

6A

SUM ALARM TB2


RAPCON FUNCTION SELECTION RAPCON FUNCTION SELECTION

1999.05.19 10:23:45

SETFUNCTION

9. PROGRAMSET NO?

8. DISPLAY REAL TIME?

7. DISPLAY TIMES?

1. PASSWORD?

2. SET RAPPER TIMES?

3. SET REAL TIME?

4. SET AUTO ON/OFF?

5. SET MANUAL ON/OFF?

6. SET PROGRAM SETNO?

10. RAPCON ADDRESS?

11. RESET ALARM?

NEXT FUNCTION NO =

To reach a function with function 1 to 6 the RAPCON must be in LOCAL mode

Access to functions 2 to 6 possible only if pass word is answered correctly.

Acess to functions 7 to 11 does not require answering the pass word.


To reach next function number either press the required number meant for the function and press enter yes (OR) press set function repeatedly till the required function is displayed.

NEXT FUNCTION NO =

NEXT FUNCTION NO = 7 7 DISPLAY TIMES ?

7

ENTERYES


DATA COMMUNICATION CARDDATA COMMUNICATION CARD

FUNCTIONSFUNCTIONS:

Provides communication path between COMCON RAPCON & BAPCON Provides Rs-232-C serial communication between P.C. & COMCON. Provides hardware communication by-pass in case of power

failure/unit faulty. Extends sum - alarm signal for external annunciation. Provides 24V A.C. power supply to COMCON / RAPCON. Provides isolated 24V DC power supply to relay card & digital buffer

card. LED indication in case of 24V DC power supply fuse failure.


RAPCONRAPCON--2424

Supports up to 12 fields Hot-Standby feature Real Time Clock (RTC) User set parameters

Stored in NVRAM Labeling of outputs Isolated Inputs and

Outputs


RAPCON-IIRAPCON-II

RS-485 based network Only Remote operation Concealed inside the

panel RTC and NVRAM Lesser components

Remote Terminal UnitRemote Terminal Unit


RTURTU

Light weight Hand held unit

Graphical Display 64x128 pixel LCD Membrane keypad RS-485 network User interface unit for

BAPCON-II, RAPCON-II


RTUsigmaRTUsigma

Graphical User Interface 240x128 pixel LCD Tactile membrane

keypad Open standard Multi

master protocol communication

Parameter trending Alarm logging Flash based

programming

Integrated Operating SystemIntegrated Operating System


NEED FOR COMPUTER CONTROL OF ESPsNEED FOR COMPUTER CONTROL OF ESPs

Tedious manual tuning of parameters in each control. Status monitoring of large number of fields. Optimisation of ESP parameters. The need of supervision & control of ESP from UCB. Data logging, alarm logging & Graphical representation

of precipitator parameters. Communication with plant computer.


IOS CONSISTS OF …..IOS CONSISTS OF …..

BAPCON

RAPCON

IOS - PC

BHELs advanced precipitator controller.

Rapper controller.

Multitasking real time PC.


FUNCTIONS OF IOS - PCFUNCTIONS OF IOS - PC

Controls & monitors BAPCONs & RAPCONs. Closed loop control of ESP through….

Opacity algorithm. Rapping set no. Algorithm. Rapping power off algorithm. Rapping time factor algorithm. Optimiser algorithm.

Centralised monitoring & control from UCB. Alarm monitoring & print out of status.


ADVANTAGES OF IOSADVANTAGES OF IOS Wide C.R suitable for Indian conditions. Automatic optimisation of C.R. base charging. Peak & valley KV measurement. Pre-programmed rapping sequences. Reduces emission & energy consumption. Pays back investment in couple of years. Software on ROM cards. Indigenous Hardware & Software. Upgradable. Maintenance support. Customising to needs.


IOS SOFTWARE MENUSIOS SOFTWARE MENUS BAPCON MENU. RAPCON MENU. PRINTER MENU. SETUP MENU.

Opacity basedata. BAPCON basedata. Rapcon basedata. Communication interval time. Algorithm basedata. Password setting. Opacity basedata. Opacity/dust correlation. Precipitator basedata.

ALGORITHM. Opacity algorithm. Optimiser algorithm. Rapping factor algorithm. Rapping power algorithm.


ALGORITHMS IN IOSALGORITHMS IN IOS

• Opacity algorithm• Rapping power off algorithm• Rapping set no. Algorithm• Optimizer algorithm• Rapping power factor algorithm• Auto selection of opacity monitor based on ID

fan status.


RAPPING FACTOR ALGORITHMRAPPING FACTOR ALGORITHM

100

75

50

25

25.5

4.0

1.0

25% 750% 100%Boiler load

Boiler load max set

Boiler load min.set

Tim

e fa

ctor

Rep

etiti

on fr

eq %


OPTIMIZER ALGORITHMOPTIMIZER ALGORITHMC.R

OPTIMISATION S/W

TAKE VI CURVE & TESTFOR VALLEY KV DROPPINGFOR OPERATING CHARGE

RATIO

DROOPING ?

INCREASE C.R. & SWITCH OFF OPTIMUM REACHED

LED.

DECREASE C.R & TEST FORDROOPING

YES NO

DROOPING ?

SWITCH OFF OPTIMUM REACHED

LED.

NO INCREASE C.R & SWITCH ON OPTIMUM

REACHEDLED.

YESRET

RET

RET


NT-IOSNT-IOS

Windows based IOS Integrated Datalogging Track Ball & Mouse

operation Industrial Computing

platform Industrial grade desktop

mounting

NT-IOSNT-IOS

Integrated Operating System on Integrated Operating System on Windows NT platformWindows NT platform

Bharat Heavy Electricals Limited, Ranipet


Main featuresMain features

• Graphical User Interface• Trend curves display• Compatibility with latest printers• User friendly help features• Information access through Intranet• can be upgradable easily


GUIGUI

User friendly windows screens for giving command to different controllers and displaying the ESP field status.


Trend curves displayTrend curves display

• VI curve for each field• Line Graphs for

• Current , Voltage, • Spark rate, • Opacity and • boiler load

• Bar chart for Analog input of Opacity and boiler load


Compatibility for PrintersCompatibility for Printers

• All printers supported by Windows NT can be used for Text log , Graph log and VI curves


User friendly help featuresUser friendly help features

• Help feature covers the Technical and operating details of this package with Images.

• Context sensitive help for each screen is available.


Information access through IntranetInformation access through Intranet

• ESP field operating parameters like TR ON/OFF , current , voltage, Rapper On/OFF etc. are made available to all intranet users through a JSP software.


Future upgradeFuture upgrade

• New customer requirements can be added easily

• Can be upgraded easily for latest / future versions of Microsoft Windows Operating Systems. ( Eg. Windows 2000 and latest)


Software ArchitectureSoftware Architecture

Windows NT O.SControls ActiveX controlsDevice Drivers

Forms & Modules

VB application program


Software detailsSoftware details• Developed in VB• 35 Forms for user input and output• 8 modules for start-up & algorithms• Active X controls

• MSCOM for communication• Graphics Server for Graphs

• Dedicated Help Package is used• Device driver for Reading Digital & Analog

channels


Salient FeaturesSalient Features• Pass word protection at two levels• Communication channel health monitoring

& indication at relevant forms• Operator’s input validation • Warning messages• Web server to publish WEB page

developed in JSP• Successfully tested at Mettur TPS &

Ramagundam STPS


NT-IOSPC

BAPCON1 BAPCON2

NT-IOS HARDWARE ARCHITECTURENT-IOS HARDWARE ARCHITECTURE

RAPCON-n RAPCON2

BAPCON-n

RAPCON-1

Boiler loadOpacity


Hardware Configuration of NT-IOSHardware Configuration of NT-IOS

Opacity monitor & calib.input

Boiler load

DATA-LOGGER PC

PRINTER

SUPPOR TINS

HEATER

SHAFTINS

HEATER

ESP

BUS SECTI ON 1

ESP

BUS SECTI ON 2

FIELD- 1

FIELD- 2

FIELD- 3

FIELD- 4

FIELD- 5

FIELD- 6

FIELD- 7

FIELD- 8

HOPPERHEATER

ESP

1 2

ALILOW

ESP

1 2

BHELSTATCON-E1

REBOOT

ALIVE

SUPPORTINS

HEATER

SHAFTINS

HEATER

ESP

BUS SECTI ON 1

ESP

BUS SECTI ON 2

FIELD-1

FIELD-2

FIELD-3

FIELD-4

FIELD-5

FIELD-6

FIELD-7

FIELD-8

HOPPER

HEATERESP

1 2

ALI

LOWESP

1 2

BHELSTATCON-E2

REBOOT

ALIVE

RAPCON 4

RAPCON 1

BAPCON 1

BAPCON 2

BAPCON 3

BAPCON24

NT- IOS PC


Hardware Configuration of NT-IOSHardware Configuration of NT-IOS


Boiler load

DATA-LOGGER PC

PRINTER

SUPPORTINS

HEATER

SH AFTINS

HEAT ER

ESP

BUS SECT ION 1

ESP

BUS SECT ION 2

FIELD-1

FIELD-2

FIELD-3

FIELD-4

FIELD-5

FIELD-6

FIELD-7

FIELD-8

HOPPERHEATER

ESP

1 2

ALILOW

ESP

1 2

BHELSTATCON-E1

REBOOT

ALIV E

SU PPORTINS

HEAT ER

SHAFTINS

HEATER

ESP

B US SECTION 1

ESP

B US SECTION 2

FIELD- 1

FIELD- 2

FIELD- 3

FIELD- 4

FIELD- 5

FIELD- 6

FIELD- 7

FIELD- 8

H OPPERH EATER

ES P

1 2

ALIL OWES P

1 2

BHELSTATCON-E2

R EBOOT

A LIVE

RAPCON 4

RAPCON 1

BAPCON 1

BAPCON 2

BAPCON 3

BAPCON24

NT- IOS PC

Fat Client

Thin Client

Any Pc withLan

IOS-1

IOS-2


Opening ScreenOpening Screen


BAPCON DisplayBAPCON Display


RAPCON DisplayRAPCON Display


ANALOG Display - BAPCONANALOG Display - BAPCON


Command ScreenCommand Screen


BAPCON CommandBAPCON Command


RAPCON CommandRAPCON Command


SETUP - SelectionSETUP - Selection


SETUP-BAPCON Base DataSETUP-BAPCON Base Data


ALGORITHM SELECTIONALGORITHM SELECTION


Graph Log - SelectionGraph Log - Selection


Graph LogGraph Log


SELECT BAPCON for VI CurveSELECT BAPCON for VI Curve


VI Curve - BAPCON1VI Curve - BAPCON1


HELPHELP


STATCON-D1MASTER

STATCON-D1SLAVE

STATCON-D2MASTER

STATCON-D2SLAVE

STATCON-D3MASTER

STATCON-D3SLAVE

STATCON-D4MASTER

STATCON-D4SLAVE

STATCON-E

COMCON

BAPCON -16

BAPCON - 1

IOS PC

1 - 16 DCVCONTROLLER

17 - 32 DCVCONTROLLER

HCCCONTROLLER

DAMPER, BWE

& LCCCONTROLLER

BAPCON 2

BAPCON - 3

RAPCON MASTER

RAPCON SLAVE

DDCMIS


Hardware Configuration of IOS with NetworkHardware Configuration of IOS with Network


Boiler load

DATA-LOGGER PC

PRINTER

RAPCON 4

RAPCON 1

BAPCON 1

BAPCON 2

BAPCON 3

BAPCON24

NT- IOS PC SERVER

Pc - 1

Pc - 2

Pc - in LAN

IOS-1

IOS-2

RS 232

LAN

RS 232 / CURRENT LOOP CONVERTER

Net08.ico

COM 1COM 2

NERWORK RJ45

CURRENT LOOP

Optional

Common IOSCommon IOS


CENTRALISED CONTROL & DISPLAY FOR MULTIPLE IOS’s CENTRALISED CONTROL & DISPLAY FOR MULTIPLE IOS’s

IOS #6

IOS #7

IOS #8

IOS #9

IOS #10

IOS #11

CIOS PC

RS-232C TO RS-485 CONVERTOR


COMMON TERMINAL FOR MULTIPLE IOS’COMMON TERMINAL FOR MULTIPLE IOS’

CENTRALISED CONTROL SYSTEM CONTROL & DISPLAY FOR INDIVIDUAL SUB-

CONTROLLERS THROUGH IOS INTERFACE : RS-232C TO RS-485 PROTOCOL : MODBUS ( ASCII ) WINDOWS BASED APPLICATION SOFTWARE


BAPCON COMMAND SCREEN BAPCON COMMAND SCREEN


RAPCON COMMAND SCREENRAPCON COMMAND SCREEN


RAPCON STATUS DISPLAYRAPCON STATUS DISPLAY


CURRENT LOOP vs MULTIDROP DATAHIGHWAYCURRENT LOOP vs MULTIDROP DATAHIGHWAY

By pass relay is required in case controller is removed / fails

Network has to be physically re configured if there is a breakage in main communication line.

Low protocol overhead, more efficient at low speeds itself.

communication frames of varying sizes allowed.

Termination resistance & by pass relay is required in case controller is removed / fails.

Network has to be physically re configured if there is a breakage in main communication line.

Protocol overhead is high, therefore higher speed is must.

Communication frame size standardized. Large message will have to be split.


Other DevelopmentsOther Developments

Wireless access between controllers Wireless access between sensors & controllers SCADA based IOS


Thank YouThank You

advanced control systems for esp 3

Documents

corona copyright

ranipet rapping system

o o o o tr temp high

rapping time

o warning alarms

base voltage

base charging

mode selection