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 controllers 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.

 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?

Operational Objectives
1. 2. 3. 4. 5.

Safety Production Specifications Environmental Regulations Operational Constraints Economics

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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

DRIVE CONTROL LEVEL 2 3 4 5 6 7 8 .. N

SWITCH GEAR / MOTOR CONTROL CENTER

Low

PROCESS
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Components of DDCMIS
MAN MACHINE INTERFACE & PROCESS INFORMATION SYSTEM

DATA COMMUNICATION SYSTEM

( DATA HIGHWAY)

CONTROL 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..

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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..

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

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Intra plant Bus..

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PROCONTROL H/W LIBRARY

INPUT MODULES

OUTPUT MODULES

CONTROLLER MODULES

INTERFACE

. BK02 . XV7713 ANALOG . EA01 . EA02 . EA03 . EA04 BINARY . EB01 . EB02 . EB03 . EB10 ANALOG . AA01 . AA02 BINARY .AB01 .AB02 TRA . DIRS . XV7715 PROCS . PR03 . PR05 . XV7717 . XV7718 . FA01 . BK03 . BA01 ANALOG . AS06 BINARY .AS04

DRIVE MODULES

. BV01 . BV05 . FV01

POWER SUPPLY
. XT382 . XT383 .XT370

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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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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

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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

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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

Type
EA01

Application
0 - 20 mA or 0 - 10 VDC

Description
4 channel 2 code sw for address setting Selection of input via jumpers.*
4 channel 2 code sw for address setting 16- 24vDC supply for txr.* RTD(Pt 100) 4 channel 2 code sw for address setting Linearisation for measurement.* Thermoelectric voltages Correction with coldjunction temperture 8 channel 2 code sw for address setting Linearisation for measurement.*
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EA02

4 20 mA

EA03

Temperature measurement

EA04

Temperature measurement

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I/O Modules..

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

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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

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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

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SOFTWARE

Programming Language Procontrol P10

Basic Functions Time functions Multi functions Functional blocks

for processor
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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 ORed 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 :500900 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
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

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TURBINE TRIP
Axial Displacement Axial Displacement

>1

Axial Displaceme nt Very High

Shaft Vibration Very High

>1
GCB closed Gen class A trip
& >1

Gen class B trip

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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

Control oil Pressure Very Low

2/3 Logic

HP Steam Pr Very High

2/3 Logic

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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

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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

Shaft Vibration Very High >1

HOUSING V V.HIGH

>1

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