introduction to control engineering at power plantsalkar/sec510/introduction... · 9 –engineering...
TRANSCRIPT
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Introduction to
Control Engineering
at Power Plants
Lesson 3
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9 – Engineering StepsDetermination of configuration
Page 2
• Components of the new DCS
control system are determined
to comply with customer
technical requirements
• General configuration overview
is prepared
• Detailed network connection
plan is prepared
• Order codes of the
components are listed
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9 – Engineering StepsConfiguration of 3rd party communication interface
Page 3
• Determination of the 3rd party
communication protocol
• Redundant or singular,
controlling station (master,
slave), network topology (point
to point, multipoint)
• Signal list of exchange signals
with communication
addresses, data volume
• Data format
• Physical layer of the
communication (RS232,
RS422, RS485, Ethernet, full
of half duplex, data Rate,
transmission distance)
• Type and length of the
communication cables
• Type and quantity of
converters, repeaters
• Definition of battery limit
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9 – Engineering StepsFinalization of signal list
Page 4
1RB13P003 Hot reheat steam pressure FUM 230 AI 2 wire
1RB21P003 XQ01 IP bypass LH outlet pressure FUM 230 AI 4 wire
1RB21S003 IP bypass LH control valve FUM 280 AO CLC
1RB21S003 XQ01 IP bypass LH control valve position FUM 230 AI 2 wire
1RB21T003 XQ01 IP bypass LH outlet temperature FUM 230 AI 2 wire
1RB22P003 XQ01 IP bypass RH outlet pressure FUM 230 AI 4 wire
1RB22S003 IP bypass RH control valve FUM 280 AO CLC
1RB22S003 XQ01 IP bypass RH control valve position FUM 230 AI 2 wire
1RB22T003 XQ01 IP bypass RH outlet temperature FUM 230 AI 2 wire
1RM21S002 IP bypass LH spray control valve FUM 280 AO CLC
1RM22S002 IP bypass RH spray control valve FUM 280 AO CLC
1SA11P002 XQ01 Curtis stage steam pressure FUM 230 AI 4 wire
• The next step is the finalization
of signal list
• There are two approaches for
finalization of the signal list:
1) Process supplier prepares
the signal list for new built plants
2) DCS supplier prepares the
signals list for control system
refurbishment projects of existing
plants.
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9 – Engineering StepsAssignment of signals to the modules
Page 5
• Assignment of signals to the
input output modules
• Process redundancy is taken
into consideration while
assignment
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9 – Engineering StepsPlaning field connection and cabinet projects
Page 6
• Interconnection diagrams,
cable lists, cable routes,
connection typicals, terminal
plans, cabinet arrangement
drawings, circuit diagrams
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9 – Engineering StepsDrawing HMI screens
Page 7
• Drawing HMI screens based
on P&I diagrams or draft
displays
• Linking dynamic elements with
function blocks
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9 – Engineering StepsForming function diagrams
Page 8
• These diagrams or, in
other words, software
program runs in the
background when the
plant is in operation.
• The function blocks read the signals on the input
cards, process and send them to the output cards,
operator screens, alarm, report pages and archive.
• Function diagrams are formed based on the task
description documents.
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9 – Engineering StepsProcurement, manufacturing and factory tests
Page 9
• The components of the control system are
procured. Cabinet components are installed in
cabinets during manufacturing in workshop.
• When the cabinet manufacturing is completed, it is
checked whether the mechanical structure and
electrical connections are completed according to
the project and standards. Similar conformity
checks are also made for equipment that are not
mounted in the cabinet.
• A factory test is performed with the optional
participation of the customer. The integrity,
suitability and functionality of the cabinets, external
components and documentation are checked once
again together with the customer.
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9 – Engineering StepsDismantling and installation
Page 10
• When the control system components arrive at the
power plant, installation works can start. Prior to
that dismantling works are necessary for
refurbishment projects.
• Some of the tasks are:
Dismantling and mounting of the cabinets, cable
laying and termination, installation of field devices
and boxes, etc.
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9 – Engineering StepsCommissioning steps
Page 11
Commissioning of
I&C configuration
Receiving inspection
and preparation of
commissioning for DCS
Switching on the DCSCommissioning of 3rd
party interfacesInstallation
DCS
Testing safety instrumented functions
(authority, adviser, customer)
Commissioning under operating conditions
(higher-level open-loop and closed-loop controls)
Process commissioning: Functions (individual/
drive /sub-loop/sub-group control, drive switch over)
Alarm optimization,
load cability test
Commissioning of process technology
Conducttrial run Acceptance
Cold function testing
System commissioning
Field signal and
equipment
testing
Supply power for
auxiliary and special
cabinets (Field)
- Continuously motor- Open loop and closed loop actuator, Solenoid valve control- Binary transducer- Analog measurement- Black Box
Field commissioning
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10 - Engineering ToolsHW engineering tool
Page 12
Loop Drawings Cabinet Arrangement Symbol Library Document Query
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10 - Engineering ToolsHW engineering tool (Cabinet arrangement)
Page 13
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10 - Engineering ToolsHW engineering tool (Terminal table)
Page 14
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10 - Engineering ToolsHW engineering tool (Loop drawing)
Page 15
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10 - Engineering ToolsHW engineering tool (Outputs-table of contest)
Page 16
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10 - Engineering ToolsHW engineering tool (Outputs-bus overview)
Page 17
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10 - Engineering ToolsHW engineering tool (Outputs-power supply)
Page 18
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10 - Engineering ToolsHW engineering tool (Outputs-power supply)
Page 19
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10 - Engineering ToolsHW engineering tool (Outputs-cabinet arrangement)
Page 20
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10 - Engineering ToolsHW engineering tool (Outputs-terminal table)
Page 21
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10 - Engineering ToolsHW engineering tool (Outputs-part list)
Page 22
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10 - Engineering ToolsHW engineering tool (Outputs-loop drawing)
Page 23
DCS cabinet MCC cabinet
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10 - Engineering ToolsHW engineering tool (SW-HW tools navigation)
Page 24
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10 - Engineering ToolsHW engineering tool (SW-HW tools navigation)
Page 25
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10 - Engineering ToolsSW engineering tool (Login)
Page 26
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10 - Engineering ToolsSW engineering tool (Workbench)
Page 27
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10 - Engineering ToolsSW engineering tool (Workbench)
Page 28
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10 - Engineering ToolsSW engineering tool (Diagram editor)
Page 29
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10 - Engineering ToolsSW engineering tool (Diagram editor)
Page 30
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10 - Engineering ToolsSW engineering tool (Diagram editor)
Page 31
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10 - Engineering ToolsSW engineering tool (Plant display)
Page 32
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10 - Engineering ToolsSW engineering tool (Trend display)
Page 33
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10 - Engineering ToolsOperation view
Page 34
Project View
Trends
TAG-Browser
Alarm Display
Diagnostic View
ReportsPoint View
Parameter Set 2Parameter Set 1 Parameter Set 3
Function Diagram
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Page 35
Thank you