STG Process Control System - Procontrol

Date: 14/03/2012

Liji P

C & I

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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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1. Safety

2. Production Specifications

3. Environmental Regulations

4. Operational Constraints

5. Economics

Operational Objectives

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UnitLevel

Function groupLevel

SUB GROUP LEVEL

Sub loopControl

Sub loopControl

Sub loopControl

DRIVE CONTROL LEVEL1 2 3 4 5 6 7 8 ….. N

SWITCH GEAR / MOTOR CONTROL CENTER

DE

GR

EE

OF

AU

TO

MA

TIO

N

PROCESS

HIERARCHY OF CONTROL

Individual Equipment and

drives

Particular Process

Low

High

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Components of DDCMIS

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CONTROL SYSTEM

DATA COMMUNICATION SYSTEM

( DATA HIGHWAY)

MAN MACHINE INTERFACE & PROCESS INFORMATION

SYSTEM

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Architecture

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Main Characteristics

Based on serial bus architecture Modular hardware and software

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Components of DDCMIS

Functional Division– S&G - C&I system– T&G - C&I system– BOP - C&I system

Hardware Components

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Data Transmission

Serial bus Two levels

– Local Bus P13– Intraplant bus P42

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Process control System

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Local Bus

Heart of the station and connects to all modules in the station

Features Transmission reliability

– Parity check, cyclic transmission, data valency , clock signal

Redundancy Time cycle : 40ms Type of modulation : Pulse modulation No of addresses : 256

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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

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Local Bus..

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Local Bus..

15

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Local Bus..

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Intra plant Bus Link all station with local bus, process computer with

diagnostic station with redundant line Features

Transmission reliability– Parity check, 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

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Intra plant Bus..

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Intra plant Bus..

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Intra plant Bus..

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Intra plant Bus..

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Intra Plant Bus..

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Type Application Description

BV01 Local bus traffic director

FA01 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

FK01 Contains FA01 modules

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Intra plant Bus..

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PROCONTROL H/W LIBRARY

ANALOG

. EA01

. EA02

. EA03

. EA04

BINARY

. EB01

. EB02

. EB03

. EB10

OUTPUTMODULES

ANALOG

. AA01

. AA02

CONTROLLERMODULES

TRA . DIR’S

. BV01

. BV05

. FV01

BINARY

.AB01

.AB02

PROC’S

. PR03

. PR05

INTERFACE

. BK02

. XV7713

. XV7715

. XV7717

. XV7718

. FA01

. BK03

. BA01

POWER SUPPLY

. XT382

. XT383

.XT370

DRIVEMODULES

ANALOG

. AS06

BINARY

.AS04

INPUTMODULES

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Control Modules

Two basic type of modules– Individual control modules– Universal control modules

Individual control modules– Implemented to control,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

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Control Module..

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Control Module..

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Redundant Communication via local bus

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BA

BV

AB

PR

EBEA

1A032F

2A

AA

3F

ORDER

ORDER

ACTUAL VALUE

ADDRESS

CLOCK

DATA

DATA

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Processor Module..

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Type Application Description

PR05 4 channel2 code sw for address setting

4 channel2 code sw for address settingShort circuit proof supply to contacts

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IO Modules

Mounted on local bus Both normal and reverse data Functions – Power to transmitter/switches

Signal Veriication – power, Zero/Span

Digitalization – 10 bit data,sign,disturbance

Address allocation

Serial/Pareellel Conversion

-

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Address allocation

Via code switches

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IO Modules

Power for transmitters and transducers Signal verification Digitalization Address allocation Serial / Parallel conversation Process interface

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I/O Modules.. Analog Input modules

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Type Application Description

EA01 0 - 20 mA or 0 - 10 VDC 4 channel2 code sw for address settingSelection of input via jumpers.*

EA02 4 – 20 mA 4 channel2 code sw for address setting16- 24vDC supply for txr.*

EA03 Temperature measurement RTD(Pt 100)4 channel2 code sw for address settingLinearisation for measurement.*

EA04 Temperature measurement Thermoelectric voltagesCorrection with coldjunction temperture8 channel2 code sw for address settingLinearisation for measurement.*

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I/O Modules.. Binary Input modules

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Type Application Description

EB01 24vdc binary signalConversion of 0/24v to local bus signal

16 channel2 code sw for address setting

EB02 Interrogation voltage of 48vdcConversion of 0/24v to local bus signal

16 channel2 code sw for address settingShort circuit proof supply to contacts

EB03 Module for supervised contactFive double throw contactNo effect on earth fault

5 channel2 code sw for address settingLinearisation for measurementShort circuit proof supply to contacts*

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I/O Modules.. Analog Output modules

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Type Application Description

AA01 Voltages 10Vdc 4 channel2 code sw for address setting

AA02 For 0- 20 mA 4 channel2 code sw for address settingShort circuit proof supply to contacts

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I/O Modules.. Binary Output modules

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Type Application Description

AB01 16 channel2 code sw for address setting

AB02 Interrogation voltage of 48vdcConversion of digital local bus signal into output with potential free contacts

16 channel2 code sw for address setting

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SOFTWARE

Programming Language– Procontrol P10– for processor Basic Functions- Functional blocks Time functions- Multi functions

Documented with – Progress 2 – Functional diagrams

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MMI

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WSPOSE

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

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VME Cage

2 way communication b/w server and IPB redundant RT20 CPU

Compatible with VME bus GBNIC

Ethernet controller RT20 CPU (bnc ) and server

PCIF

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CPU RT20 is designed using Motorola M68020 microprocessor .Power Rewuirement : +5VDC @2.5A, +12 VDC @200 MA, -12V DC @200MA

RT 20 has 6 front panel LEDs. RUN – Illuminated Green always on during running HALT- When halt condition initiated from process. OFF in healthy

condition. VME ( YELLOW) – Illuminated when RT20 acesses any resources.

Continuous flashing in healthy conditions. BLO(RED) is illuminated when Battery voltage is low.OFF during healthy

condition AP1,AP2 (GREEN YELLOW) -User application LEDs .Off during healthy

condition

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GBINC

COMMUNICATION MODULE ,2 SEPARATE ETHERNET CABLE IS CONNECTED TO SERVER 1 &2 .

Rx/Tx( RED) – ILLUMINATES WHEN RECEIVES OR SEND DATA. 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 . NORMALLY OFF

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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 .

Each PCIF acts as a local station on IPB. 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.

70CK01 is connected to coupler FA01 of Intraplant bus by means of two 8 line connecting cables

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IPB COMMUNICATION CHECK

Small window in the top right corner of OPTASK indicate the status.The user name, MW,frequency and status of server indicated in the window.

Green : Server 1 Active, Yellow : server 2 active Red :. Lone active Server status is indicated as – Active ,Standby , Lone active : This will

come when one server is active or communication between the servers are lost.

WSPOSE System will act as two local stations in the IPB with 02 and 03 as address. The address selection mis made through PCIF.

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REDUNDANCY LOGIC

Failure of one server, network link,operator station will not affect operation.

Both servers operate in parallel.Active server collects data from IPB and transmits the same to operator work station and LAN. Standby server collects data from IPB but refrain from sending it to LAN.Standby server accepts all data from Active server and operator workstations. Both servers exchange messages in every 500ms. When there is a break the other server will take up.

Server will go bad if communication failures from the VME or any data transfer error from IPB.

Control commands can be issued through FKB or mouse .Any drive can be operated from any workstation . Each work station is operating separately . Failure of one work station will not affect the other system.

In the Procontrol system ID signals are OR’ed for final controls,hence control operations proceed unhindered even if one server fails

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FUNCTIONAL KEY BOARD

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

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Thank You..

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APPENDIX

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Serial Communication

Serial Communication is the process of sending data one bit at a time, sequentially, over a communication channel or computer bus. This is in contrast to parallel communication, where several bits are sent as a whole, on a link with several parallel channels

Designer :Compaq, DEC, IBM, Intel, Microsoft, NEC and Nortel Designed :1994 Manufacturer: Intel, Compaq, Microsoft, NEC, Digital Equipment Corporation,

IBM, Nortel Signal : 5 volt DC Max. voltage: 5 V(±5%) Max. current :500–900 mA

@ 5 V (depending on version) Data signal: Packet data, defined by specifications Width: 1 bit Bitrate : 1.5/12/480/5,000 Mbit/s (depending on version) Max. devices :127 Protocol :Serial

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Client server architecture

Servers are powerful computers or processes dedicated to managing disk drives (file servers), printers (print servers), or network traffic (network servers ). Clients are PCs or workstations on which users run applications. Clients rely on servers for resources, such as files, devices, and even processing power.

File and Network security Increased reliability; decreased workflow interruptions Centralized data storage and shared resources Centralized Backup

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VME Bus

computer bus standard, originally developed by Motorola

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Thank you

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PROTECTIONS AND LOGICS

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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

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Sequence of events when turbine trips

When the turbine trips, the turbine control system immediately dumps the Hydraulic fluid from the main stop valves actuators and closes the stop valves.

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.

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TURBINE TRIP

Emergency turbine trip

Turbine speed >3300 rpm

HP Steam temp low trip

Metal temp very high >1

All HRSG Trip

Turbine Trip CMD

B

C

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TURBINE TRIP

GCB closed

>1B

Gen class A trip

Gen class B trip

Axial Displacement Very High

Shaft Vibration Very High

>1

&

Axial Displacement>1

Axial Displacement

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TURBINE TRIP

MOT Level

Lube Oil Pressure Very Low

Turb Exht Pr Very High

HP Steam Pr Very High

Control oil Pressure Very Low

2/3 Logic

2/3 Logic

2/3 Logic

2/3 Logic

2/3 Logic

>1C

Trip oil Pressure Very Low 2/3 Logic

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Metal Temp V High

GEN FJB Temp

>1

Metal Temp V High > 115 DEG C

GEN RJB Temp

Turbine TB Active

Turbine TB Non Active

Turbine FJB Temp

Turbine TB Active

Turbine TB Non Active

Turbine RJB Temp

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Shaft vibration high

GEN rear shaft vibration

>1

Shaft VibrationVery High

Turbine rear shaft vibration

Turbine front shaft vibration

GEN front shaft vibration

>1Turbine rear shaft vibration

Turbine front shaft vibration

GEN front shaft vibration

GEN front brg vibration

>1Turbine front brg vibration

Turbine rear brg vibration

GEN rear brg vibration

>1

GEN rear shaft vibration

HOUSING V V.HIGH

SHAFT V V.HIGH

SHAFT V V.HIGH