plc and ddcmis

PLCPLC&&

DDCMISDDCMIS

What is PLC?What is PLC?

Programmable Logic Controller

… a nice replacement for electromechanical relay controls

• A PLC is an industrially hardened computer-based unit that performs discrete or continuous control functions in a variety of processing plant and factory environments.

• Originally intended as relay replacement equipment for the automotive industry, the PLC can be found in some part of virtually every type of industry imaginable.

• The primary reason for designing such a device was eliminating the large cost involved in replacing the complicated relay based machine control systems.

What is PLC?

What is inside a PLC?PROGRAMMING

DEVICE

POWER SUPPLY CPU MEMORY

I/O SYSTEM MODULES

OUTPUT DEVICES

INPUT DEVICES

SOLENOIDS MOTOR STARTERS

ETC

SWITCHES PUSH BUTTONS ETC

I/O BUS

What is inside a PLC?Power Supply

It converts Power Line voltages to those required by electronic components of PLC.

It may be Integral or separately mounted.

It provides the isolation necessary to protect electronic components from most high-voltage line spikes.

It is rated for heat dissipation requirements for plant floor operation.

What is inside a PLC?Input Systems

Inputs are defined as real-world signals giving the controller real-time status of process variables.

These signals can be analog or digital, low or high frequency, maintained or momentary.

They are presented as a varying voltage, current or resistance value.

Signals from thermocouples and RTDs are common examples of analog signals.

Pushbuttons, limit switches & electromechanical relay contacts are familiar examples of digital, contact closure type signals.

What is inside a PLC?Outputs There are three common categories of outputs:

• Discreet: Pilot lights, solenoid valves, annunciator windows (lamp box)

• Register: Panel meters or displays

• Analog: Variable speed drives or I/P converters (control valves)

Most I/O systems are modular in nature; that is, a system can be arranged by use of modules that contain multiples of I/O points.These modules can be composed of 1, 4, 8, or 16 points and plug into the existing bus structure.

The bus structure is really a high-speed multiplexer that carries information back and forth between the I/O modules and the CPU.

One of the important functions of I/O is its ability to isolate real-world signals from the low signal levels in the I/O bus

What is inside a PLC?Central Processor Unit

It performs the tasks necessary to fulfill the PLC function. Among these tasks are

• Scanning

• I/O bus traffic control

• Program execution

• Peripheral & external device communications

• Self Diagnostics

One important factor which rates a PLC is scan time. It is roughly defined as the time it takes for the PLC to interrogate the input devices, execute the application program and provide updated signals to the output devices.

What is inside a PLC?Memory Unit

It is the library where the application program is stored.

It is also where the PLC’s executive program is stored. An executive program functions as the operating system of the PLC. It is the program that interprets, manages and executes the user’s application program.

It is the part of PLC where process data from the input modules and control data for the output modules are temporarily stored as data tables.

Memory can be volatile or nonvolatile. Volatile memory is erased if power is removed. Battery backup is provided for most units with volatile memory to avoid loss of program in the event of power outage.

What is inside a PLC?Programmer Unit

It provides an interface between the PLC and the user during program development, start-up and troubleshooting.

The instructions to be performed during each scan are coded and inserted into memory with the programmer.

Programmers vary from small hand-held units the size of a large calculator to desktop stand-alone intelligent CRT-based units.

Programmers come complete with documentation, reproduction, I/O status & on-line and off-line programming ability.

Many PLC use a PC as the programming tool using the serial interface and a Programming Software.

How a PLC Operates?

Step 1-CHECK INPUT STATUS-First the PLC takes a look at each input to determine if it is on or off. It records this data into its memory to be used during the next step. Step 2-EXECUTE PROGRAM-Next the PLC executes your program one instruction at a time using the input data obtained in previous step and decides about the states of output. It will store the execution results for use later during the next step.

Step 3-UPDATE OUTPUT STATUS-Finally the PLC updates the status of the outputs using the results obtained in previous step. After the third step the PLC goes back to step one and repeats the steps continuously.

How a PLC is Programmed?Ladder Diagrams• Ladder diagrams are one traditional method of describing control circuits. • There are a few basic symbols that are used to express the meaning and purpose of a control circuits. They are

Normally Open Contact

Normally Closed Contact

Normally Open Push Button

Normally Closed Push Button

(T.O.) (Time to Open)

Time Delayed Contact

Starter/Relay/ Solenoid Coil

Example PLC ProgramLet us consider a simple example. In the given circuit, the coil will be energized when there is a closed loop between the + and - terminals of the battery(When both the switches SW1 & SW2 are closed). This simple circuit is represented in a ladder Diagram as below. A ladder diagram consists of

individual rungs just like on a real ladder. Each rung must contain one or more inputs and one or more outputs. The first instruction on a rung must always be an input instruction and the last instruction on a rung should always be an output (or its equivalent).

Some PLC require that every ladder diagram include an END instruction on the last rung.

Advantages of PLCCompared with electromechanical relay systems, PLCs offer the following advantages:

Ease of programming and reprogramming in the plant.

A programming language that is based on relay wiring symbols familiar to most plant personnel

High reliability and minimal maintenance

Small physical size

Ability to communicate with computer systems in the plant

Moderate to low initial investment cost

Rugged construction

Modular design

PLC Applications at Our Project

Some of the areas using PLC are:

Coal Handling Plant Stage-II

Ash Handling Plant Stage-II

DM Water Plant Stage-II

Condenser Tube Cleaning System Stage-II

Generator Stator Water Conductivity/Flow Protections Stage-I

Boiler Feed Pump Delta-T Protection in Unit-II

WHAT IS DDCMIS ?WHAT IS DDCMIS ?DDISTRIBUTED ISTRIBUTED

DDIGITALIGITAL

CCONTROL,ONTROL,

MMONITORING &ONITORING &

IINFORMATIONNFORMATION

SSYSTEMYSTEM

Distributed means there is no centralized control and control is spread across multiple units

Digital means processing of process information is done in digital form using micro-processor based hardware

MIS interfaces the human with process using computers

• LOCAL PNEUMATIC CONTROLLERSLOCAL PNEUMATIC CONTROLLERS

• MINIATURIZED AND CENTRALIZED PNEUMATIC MINIATURIZED AND CENTRALIZED PNEUMATIC

CONTROLLERS AT CONTROL PANELS AND CONTROLLERS AT CONTROL PANELS AND

CONSOLESCONSOLES

• SOLID-STATE CONTROLLERSSOLID-STATE CONTROLLERS

• COMPUTERISED CONTROLS (SUPERVISORY)COMPUTERISED CONTROLS (SUPERVISORY)

• DIRECT DIGITAL CONTROL(DDC)DIRECT DIGITAL CONTROL(DDC)

• DISTRIBUTED MICROPROCESSOR BASED CONTROLDISTRIBUTED MICROPROCESSOR BASED CONTROL

PROGRESS OF INSTRUMENTATION USED TO IMPLEMENT

AUTOMATIC PROCESS CONTROL

DDCMIS – TECHNOLOGICAL DDCMIS – TECHNOLOGICAL BACKGROUNDBACKGROUND

Why DDCMIS?Why DDCMIS?

Disadvantages of earlier SystemsDisadvantages of earlier Systems

• Analog instrument panels required huge space, Analog instrument panels required huge space, lot of wiring and are less user friendly for lot of wiring and are less user friendly for monitoring of large number of parameters.monitoring of large number of parameters.

• Accuracy obtained with solid-state controls is Accuracy obtained with solid-state controls is not good and they tend to drift with time.not good and they tend to drift with time.

• Supervisory controls are inflexible as changing Supervisory controls are inflexible as changing of control configuration requires change in of control configuration requires change in routing of wires.routing of wires.

• Use of centralized control leads to complete Use of centralized control leads to complete failure during shutdowns.failure during shutdowns.

Components of DDCMISComponents of DDCMIS

CONTROL SYSTEM

MAN MACHINE INTERFACE & PROCESS INFORMATION SYSTEM

DATA COMMUNICATION SYSTEM

( DATA HIGHWAY)

DATA COMMUNICATION SYSTEM

• LOCAL SYSTEM BUS – It is just lines on the backplane of

control panel to which all the modules are connected directly.

It serves as communication medium between the modules.

• INTRAPLANT BUS(IPB) – It is a coaxial cable which runs

through all the panels of control system and interconnects

them.

• LOCAL AREA NETWORK(LAN) – It is a network of

computers which are connected to a single point(HUB).

SOME FORM OF REDUNDANCY IS PRESENT



FUNCTIONAL DIVISION

• SG-C&I SYSTEM

• TG-C&I SYSTEM

• BOP-C&I SYSTEM

CONTROL SYSTEM

HARDWARE COMPONENTS

• POWER SUPPLY

• CONTROL PANEL

• ELECTRONIC MODULES

SG-C&I SYSTEMSG-C&I SYSTEM

CONSISTS OFCONSISTS OF

• BURNER MANAGEMENT SYSTEM BURNER MANAGEMENT SYSTEM (BMS)(BMS)

• SOOT BLOWER CONTROL SYSTEM SOOT BLOWER CONTROL SYSTEM (SBC)(SBC)

• SECONDARY AIR DAMPER CONTROL SYSTEM SECONDARY AIR DAMPER CONTROL SYSTEM (SADC)(SADC)

• AUXILIARY PRDS CONTROLS AUXILIARY PRDS CONTROLS (APRDS)(APRDS)

• HP BYPASS SYSTEM(HP BYPASS SYSTEM(HPBPHPBP))

TG-C&I SYSTEMTG-C&I SYSTEM

CONSISTS OF CONSISTS OF

• ELECTRONIC TURBINE PROTECTION ELECTRONIC TURBINE PROTECTION (ETP)(ETP)

• AUTOMATIC TURBINE RUN-UP SYSTEM AUTOMATIC TURBINE RUN-UP SYSTEM (ATRS)(ATRS)

• AUTOMATIC TURBINE TESTING SYSTEM AUTOMATIC TURBINE TESTING SYSTEM (ATT)(ATT)

• ELECTRO- HYDRAULIC TURBINE CONTROL SYSTEM ELECTRO- HYDRAULIC TURBINE CONTROL SYSTEM (EHTC)(EHTC)

• TURBINE STRESS CONTROL SYSTEM TURBINE STRESS CONTROL SYSTEM (TSC)(TSC)

• LP BYPASS SYSTEM (LP BYPASS SYSTEM (LPBPLPBP))

• GLAND STEAM PRESSURE CONTROLGLAND STEAM PRESSURE CONTROL

• GENERATOR AUXILIARY MONITORING PANEL (GENERATOR AUXILIARY MONITORING PANEL (GAMPGAMP))

BOP-C&I SYSTEMBOP-C&I SYSTEM• CONSISTS OF OPEN LOOP CONTROL SYSTEM (CONSISTS OF OPEN LOOP CONTROL SYSTEM (OLCSOLCS) AND ) AND

CLOSED LOOP CONTROL SYSTEM (CLOSED LOOP CONTROL SYSTEM (CLCSCLCS))

• OLCS OLCS - THE SEQUENCE CONTROL, INTERLOCK OF ALL THE - THE SEQUENCE CONTROL, INTERLOCK OF ALL THE PLANT SYSTEMS WHICH ARE NOT COVERED IN THE SG-C&I PLANT SYSTEMS WHICH ARE NOT COVERED IN THE SG-C&I AND TG-C&I. THIS INCLUDES MAJOR AUXILIARIES LIKE AND TG-C&I. THIS INCLUDES MAJOR AUXILIARIES LIKE FD/ID/PA FANS, AIR-PREHEATER, BFP/CEP/CWP/ BCWP , FD/ID/PA FANS, AIR-PREHEATER, BFP/CEP/CWP/ BCWP , DMCWP/CLCWP AND ELECTRICAL BREAKERSDMCWP/CLCWP AND ELECTRICAL BREAKERS..

• CLCSCLCS - THE MODULATING CONTROL FOR VARIOUS - THE MODULATING CONTROL FOR VARIOUS

IMPORTANT PLANT PARAMETERS, LIKE FW FLOW (DRUM IMPORTANT PLANT PARAMETERS, LIKE FW FLOW (DRUM

LEVEL), FURNACE DRAFT, COMBUSTION CONTROL (FUEL LEVEL), FURNACE DRAFT, COMBUSTION CONTROL (FUEL

FLOW AND AIR FLOW), PA HDR PRESSURE CONTROL, FLOW AND AIR FLOW), PA HDR PRESSURE CONTROL,

DEAERATOR/HOTWELL/HEATER LEVEL CONTROLS ETC.DEAERATOR/HOTWELL/HEATER LEVEL CONTROLS ETC.

CONTROL SYSTEM - CONTROL SYSTEM - HARDWAREHARDWARE

PROCONTROL MODULESPROCONTROL MODULES• INPUTINPUT• OUTPUTOUTPUT• PROCESSORPROCESSOR• DRIVEDRIVE• BUS COMMUNICATIONBUS COMMUNICATION

THE CONTROL SYSTEM USED IN STAGE-II IS PROCONTROL P13/42

INPUT MODULEINPUT MODULE

It receives the process signal, convert them to It receives the process signal, convert them to digital form and communicate the value on local digital form and communicate the value on local busbus

• ANALOGANALOG– Voltage(EA01) 4-channelVoltage(EA01) 4-channel– Current(EA02) 4-channelCurrent(EA02) 4-channel– RTD(EA03) 4-channelRTD(EA03) 4-channel– Thermocouple(EA04) 8-channelThermocouple(EA04) 8-channel

• DIGITALDIGITAL– Voltage(EB01) 4-channelVoltage(EB01) 4-channel– Single contact(EB02) 16-channelSingle contact(EB02) 16-channel– Change-over contact(EB03) 5-channelChange-over contact(EB03) 5-channel


OUTPUT MODULESOUTPUT MODULES

They receive the value from localbus and give They receive the value from localbus and give output to the process/field.output to the process/field.

• ANALOGANALOG– Voltage(AA01) 4-channelVoltage(AA01) 4-channel– Current(AA02) 4-channelCurrent(AA02) 4-channel

• DIGITALDIGITAL– Voltage(AB01) 16-channelVoltage(AB01) 16-channel– Contact(AB02) 16-channelContact(AB02) 16-channel


PROCESSOR MODULE ( PR05)PROCESSOR MODULE ( PR05)

• IT IS RESPONSIBLE FOR THE EXECUTION OF ALL THE IT IS RESPONSIBLE FOR THE EXECUTION OF ALL THE LOGICS THAT IS PROGRAMMED INTO ITLOGICS THAT IS PROGRAMMED INTO IT

• IT CAN BE USED IN REDUNDANT MODEIT CAN BE USED IN REDUNDANT MODE• IT IS PROGRAMMED USING SK06 KIT, WHICH IS A IT IS PROGRAMMED USING SK06 KIT, WHICH IS A

COMPUTER BASED UNIT FOR INTERFACING WITH COMPUTER BASED UNIT FOR INTERFACING WITH PROCESSORPROCESSOR

• THE LOGICS ARE PROGRAMMED USING THE P10 THE LOGICS ARE PROGRAMMED USING THE P10 LANGUAGELANGUAGE


DRIVE MODULESDRIVE MODULES

• THESE ARE USED FOR CONTROLLING THE THESE ARE USED FOR CONTROLLING THE DIFFERENT TYPES OF PROCESS ACTUATING DIFFERENT TYPES OF PROCESS ACTUATING ELEMENTSELEMENTS

• THEY HAVE PREDEFINED LOGICS BUILT INTO THEY HAVE PREDEFINED LOGICS BUILT INTO THEMTHEM

• TYPESTYPES– ANALOG (ANALOG (AS06AS06))

• USED FOR DRIVING ANALOG CONTROL DRIVES SUCH USED FOR DRIVING ANALOG CONTROL DRIVES SUCH AS VARIABLE SPEED DRIVES, CONTROL VALVES AS VARIABLE SPEED DRIVES, CONTROL VALVES THROUGH I/P CONVERTER ETCTHROUGH I/P CONVERTER ETC

– DIGITAL (DIGITAL (AS04AS04))• USED FOR OPERATING MOTORS, ELECTRICAL USED FOR OPERATING MOTORS, ELECTRICAL

VALVES, SOLENOID VALVES ETCVALVES, SOLENOID VALVES ETC


BUS/COMMUNICATION MODULESBUS/COMMUNICATION MODULESBUS TRAFFIC DIRECTORBUS TRAFFIC DIRECTOR• IT CONTROLS THE COMMUNICATION PROCESS ON THE IT CONTROLS THE COMMUNICATION PROCESS ON THE

BUSBUS- THERE ARE TWO TYPES OF TRAFFIC DIRECTORS:- THERE ARE TWO TYPES OF TRAFFIC DIRECTORS:– LOCAL BUS(LOCAL BUS(BV05BV05))– INTRAPLANT BUS(INTRAPLANT BUS(FV05FV05))

BUS COUPLER(BUS COUPLER(BK02BK02))• IT CONNECTS THE LOCAL BUS TO THE IPBIT CONNECTS THE LOCAL BUS TO THE IPB

BUS END MODULE(BUS END MODULE(BA01BA01))• IT IS USED FOR TERMINATING THE LOCAL BUSIT IS USED FOR TERMINATING THE LOCAL BUS


LOCAL BUS – P42IPB

LOCALBUS

TRAFFICDIRECTOR

PROCESSORAnalogInput

Module

BinaryInput

Module

AnalogOutputModule

DRIVE CONTROLMODULE

Local Bus

BinaryOutputModule

Bus Coupler

AD CLK

CONTROL SYSTEM OVERVIEW

IPBTRAFFIC

DIRECTOR

BUSCOUPLER

BUSCOUPLER

BUSCOUPLER

IPBTRAFFIC

DIRECTOR

WSPOSEPANEL

SERVER

BK 02

IPB - 1

IPB - 2

Local Bus -1.0BLocal Bus

-1.0C,2.0C

Local Bus -1.0C

• VPC OPERATIONVPC OPERATION

• OTHER OPERATOR INFORMATIONS THROUGH VARIOUS OTHER OPERATOR INFORMATIONS THROUGH VARIOUS DISPLAYSDISPLAYS

• ALARMS, LOGS, HISTORICAL AND LONG TERM STORAGE.ALARMS, LOGS, HISTORICAL AND LONG TERM STORAGE.

• PERFORMANCE AND OTHER CALCULATIONSPERFORMANCE AND OTHER CALCULATIONS

MMIPIS – MAN MACHINE INTERFACE & PLANT INFORMATION

SYSTEM

Functions


PMS AND WSPOSE ARE EXAMPLES OF MMIPIS SYSTEM

WS POSE PANEL ( DDC – MMI INTERFACE PANEL )

SERVER 1

LAN

OWS 1 OWS 5

LOCAL BUS STATIONS

PS

PR05

BK

I /P I /P O/P

PS

PR

BK

I /P I /P O/P

O/P

WSPOSE OVERALL VIEW

IPB 1 & 2

SERVER 2

SG PACKAGE TG PACKAGESTATION

C & I

IPB - 1

IPB - 2

IPB - 3

IPB - 4

IPBACCESS

COUPLER

LAN

OWS -1 OWS -2 OWS -3 OWS -4

SERVER2 SERVER1

WORKSTATIONSPMS PANEL

PMS SYSTEM

WHY DDCMIS ?WHY DDCMIS ?1. VERY HIGH FLEXIBILITY FOR 1. VERY HIGH FLEXIBILITY FOR

MODIFICATION IN CONTROL STRATEGYMODIFICATION IN CONTROL STRATEGY

2. VERY HIGH SELF-DIAGNOSTIC2. VERY HIGH SELF-DIAGNOSTIC

3. VERY LOW DRIFT (ONLY IN I/O CARDS) , 3. VERY LOW DRIFT (ONLY IN I/O CARDS) ,

HENCE NO NEED OF FREQUENT RE-HENCE NO NEED OF FREQUENT RE-

CALIBRATIONCALIBRATION

4. MUCH HIGHER RELIABILITY (BASED ON 4. MUCH HIGHER RELIABILITY (BASED ON

MTBF)MTBF)

5. BETTER LONG TERM SUPPORT DUE TO 5. BETTER LONG TERM SUPPORT DUE TO

CHANGING TECHNOLOGYCHANGING TECHNOLOGY

6. MUCH BETTER OPERATOR INTERFACE6. MUCH BETTER OPERATOR INTERFACE

PLC & DDC - COMPARISION

• DCS systems are used for large applications and closed loop controls, whereas, PLC are primarily used for small applications and sequential controls.

• DCS systems are very costly for small applications, whereas, PLCs are much cost-effective for both small and large applications.

• While DCS systems are superior in communication redundancy and data security, PLCs are better for logic, are faster and have more rugged I/O.

• DCS systems are more difficult to design than PLCs.

SALIENT FEATURES OF SALIENT FEATURES OF DDCMISDDCMIS

SALIENT FEATURES OF DDCMISSALIENT FEATURES OF DDCMIS

• INTEGRATED PLANT CONTROL FOR INTEGRATED PLANT CONTROL FOR SG, TG AND BALANCE OF PLANT SG, TG AND BALANCE OF PLANT CONTROL CONTROL IT MAY BE REMEMBERED THAT IT MAY BE REMEMBERED THAT HISTORICALLY THE TERM DDCMIS USED BE HISTORICALLY THE TERM DDCMIS USED BE REFERRED TO FOR THE SO-CALLED REFERRED TO FOR THE SO-CALLED “BOP-C&I”“BOP-C&I” . . THE SG-C&I, i.e. FSSS etc. TG-C&I i.e. ATRS, THE SG-C&I, i.e. FSSS etc. TG-C&I i.e. ATRS, TURBINE PROTECTION etc. ORIGINALLY WERE TURBINE PROTECTION etc. ORIGINALLY WERE NOT CONSIDERED UNDER NOT CONSIDERED UNDER DDCMISDDCMIS OR OR DCS DCS AS AS PER MANY SUPPLIERS. ONLY RECENTLY THE PER MANY SUPPLIERS. ONLY RECENTLY THE TYPE OF SYSTEMS FOR ALL THE SYSTEMS HAVE TYPE OF SYSTEMS FOR ALL THE SYSTEMS HAVE BECOME SIMILAR (WITH SOME DIFFERENCE BECOME SIMILAR (WITH SOME DIFFERENCE WHICH WILL BE DISCUSSED LATER), WE TEND WHICH WILL BE DISCUSSED LATER), WE TEND TO CONSIDER THESE SYSTEMS UNDER DDCMIS.TO CONSIDER THESE SYSTEMS UNDER DDCMIS.


• INTEGRATED PLANT OPERATION INTEGRATED PLANT OPERATION THROUGH FULLY INTERCHANGEABLE THROUGH FULLY INTERCHANGEABLE OPERTAOR WORK STATIONS (OWS) OPERTAOR WORK STATIONS (OWS) FOR SG, TG AND BALANCE OF PLANT FOR SG, TG AND BALANCE OF PLANT (SOMETIMES THIS MAY NOT BE (SOMETIMES THIS MAY NOT BE POSSIBLE DUE TO PACKAGING CONCEPT)POSSIBLE DUE TO PACKAGING CONCEPT)


• PROVISION OF EXTENSIVE SELF-PROVISION OF EXTENSIVE SELF-DIAGNOSTICSDIAGNOSTICS

• USE OF LARGE VIDEO SCREENS FOR USE OF LARGE VIDEO SCREENS FOR PROJECTIONS OF VARIOUS PLANT PROJECTIONS OF VARIOUS PLANT MIMICS ETC.MIMICS ETC.

• PROVISION OF FAULT ALARM PROVISION OF FAULT ALARM ANALYSIS TO GUIDE THE OPERATOR ANALYSIS TO GUIDE THE OPERATOR TO THE MOST LIKELY EVENTTO THE MOST LIKELY EVENT

• PROVISION OF TREND ALARMSPROVISION OF TREND ALARMS


• PROVISION OF SAFETY HARDWARE PROVISION OF SAFETY HARDWARE FOR BURNER MANAGEMENT SYSTEMS FOR BURNER MANAGEMENT SYSTEMS

• PROVISION OF FAIL-SAFE HARDWARE PROVISION OF FAIL-SAFE HARDWARE FOR TURBINE PROTECTION SYSTEMFOR TURBINE PROTECTION SYSTEM

• PROVISION OF ADEQUATE RELIABILITY PROVISION OF ADEQUATE RELIABILITY AND AVAILABILITY WITH PROPER AND AVAILABILITY WITH PROPER REDUNDANCY IN SENSOR, I/O AND REDUNDANCY IN SENSOR, I/O AND CONTROLLER LEVELS.CONTROLLER LEVELS.

DDCMIS CONFIGURATIONDDCMIS CONFIGURATION

HMIREDUNDANT SERVERS

Redundant F.G.Controllers

ENGG.STN.FOR CONTROL SYS.

HMIENGG. STN FOR HMI

PROCONTROL SYSTEM

Measurement system / I/O subsystem

I.P. BUS Max. 4 nos. rdundant

maxDNA SYSTEM

MMI LAN

CONTROL SYSTEMCONTROL SYSTEM

CONTROL SYSTEM

PROGRAMMING & MMIPIS M & SCONFIGURATION SYSTEM CLOCK

SG- C&I BOP- C&I TG- C&ISYSTEM SYSTEM SYSTEM

DCS

2 X 100 %CONTROLLERS (INCL. COMM. CONT.)

LOCAL BUS

I/O CARDS DCMS **

DCS

FUNCTIONAL GROUPSFUNCTIONAL GROUPS• SIGNIFICANT REDUCTION IN SIGNIFICANT REDUCTION IN

NUMBERS EXPECTED IN NUMBERS EXPECTED IN FORTHCOMING PROJECTSFORTHCOMING PROJECTS

• COMBINING OF OLCS AND CLCS COMBINING OF OLCS AND CLCS CONTROLLERS - CONTROLLERS - HISTORICAL HISTORICAL BACKGROUNDBACKGROUND

• EXCEPT FOR CERTAIN SUPPLIERS, EXCEPT FOR CERTAIN SUPPLIERS, ALL HAVE VERY POWERFUL ALL HAVE VERY POWERFUL CONTROLLERSCONTROLLERS

• TRANSPARENCY 6,7,8 FOR GROUP DRAWINGSTRANSPARENCY 6,7,8 FOR GROUP DRAWINGS

MMIPISMMIPIS

MAN-MACHINE INTERFACE MAN-MACHINE INTERFACE AND PLANT INFORMATION AND PLANT INFORMATION SYSTEMSYSTEM

• LATEST STATE-OF-THE-ART WORKSTATIONS LATEST STATE-OF-THE-ART WORKSTATIONS AND SERVERS BASED ON OPEN-ARCHITECTURE AND SERVERS BASED ON OPEN-ARCHITECTURE AND INDUSTRY STANDARD HARDWARE AND AND INDUSTRY STANDARD HARDWARE AND SOFTWARE TO ENSURE BETTER CONNECTIVITY.SOFTWARE TO ENSURE BETTER CONNECTIVITY.

• e.g. HARDWARE FROM COMPAQ/DIGITAL, HP, e.g. HARDWARE FROM COMPAQ/DIGITAL, HP, SUN MICRO-SYSTEM OR OTHER MAJOR SUN MICRO-SYSTEM OR OTHER MAJOR SUPPLIERS SUPPLIERS (LESS DEPENDENCE ON THE C&I (LESS DEPENDENCE ON THE C&I SYSTEM SUPPLIER IN THE LONG RUN)SYSTEM SUPPLIER IN THE LONG RUN)

• OPERATING SYSTEM WINDOWS-NT, OPEN-VMS OPERATING SYSTEM WINDOWS-NT, OPEN-VMS OR UNIX.OR UNIX.

MAN-MACHINE INTERFACE MAN-MACHINE INTERFACE AND PLANT INFORMATION AND PLANT INFORMATION SYSTEMSYSTEM• 64-BIT SERVER/OWS WITH HIGH-SPEED 64-BIT SERVER/OWS WITH HIGH-SPEED

AND LARGE MEMORY (256/512 MB RAM, 8 AND LARGE MEMORY (256/512 MB RAM, 8 GB HDD FOR SERVER AND 128/256 MB GB HDD FOR SERVER AND 128/256 MB RAM AND 4/6 GB HDD FOR OWS) RAM AND 4/6 GB HDD FOR OWS) TO TO ENSURE FAST RESPONSEENSURE FAST RESPONSE

• PROVISION OF LVSPROVISION OF LVS

• CONNECTION TO OTHER SYSTEM CONNECTION TO OTHER SYSTEM THROUGH STATIONWIDE WANTHROUGH STATIONWIDE WAN

• TRANSPARENCY NO 9 & 10TRANSPARENCY NO 9 & 10

MMIPIS FUNCTIONALITIESMMIPIS FUNCTIONALITIES

• VPC OPERATIONVPC OPERATION

• OTHER OPERATOR INFORMATIONS OTHER OPERATOR INFORMATIONS THROUGH VARIOUS DISPLAYSTHROUGH VARIOUS DISPLAYS

• ALARMS, LOGS, HISTORICAL AND ALARMS, LOGS, HISTORICAL AND LONG TERM STORAGE.LONG TERM STORAGE.

• PERFORMANCE AND OTHER PERFORMANCE AND OTHER CALCULATIONSCALCULATIONS

DCSDCS

REDUNDANT DATA REDUNDANT DATA COMMUNICATION SYSTEM COMMUNICATION SYSTEM (DCS)(DCS)

• 1. MAIN SYSTEM BUS1. MAIN SYSTEM BUS

• 2. LOCAL SYSTEM BUS2. LOCAL SYSTEM BUS

• 3. LOCAL BUS OR I/O BUS3. LOCAL BUS OR I/O BUS

• 4. OWS LAN4. OWS LAN

• 5. STATION-WIDE WAN5. STATION-WIDE WAN

DDCMIS CONFIGURATIONDDCMIS CONFIGURATION

HMIREDUNDANT SERVERS

Redundant F.G.Controllers

ENGG.STN.FOR CONTROL SYS.

HMIENGG. STN FOR HMI

PROCONTROL SYSTEM

Measurement system / I/O subsystem

I.P. BUS Max. 4 nos. rdundant

maxDNA SYSTEM

MMI LAN

UNIT C&ISYSTEM(TYP)

OFF-SITE C&I SYSTEM

(TYP)

OFF-LINE LAN

STATION-WIDE ON-LINE LAN

GATEWAY TO CORP. CENTRE

OTHERUNITS

POWER SUPPLY SYSTEMPOWER SUPPLY SYSTEM

• CONTROL SYSTEM POWER SUPPLYCONTROL SYSTEM POWER SUPPLY TWO TWO SETS OF DC POWER SUPPLIES - ONE SET SETS OF DC POWER SUPPLIES - ONE SET FOR SG/TG-C&I AND OTHER FOR BOP-C&I FOR SG/TG-C&I AND OTHER FOR BOP-C&I EACH WITH 2 X 100 % CHARGER AND 2 X EACH WITH 2 X 100 % CHARGER AND 2 X 100 % BATTERY.100 % BATTERY.

• OTHER IMPORTANT AC LOADS LIKE MMIPIS, OTHER IMPORTANT AC LOADS LIKE MMIPIS, PANEL INSTRUMENTS, ANALYSERS ETC. PANEL INSTRUMENTS, ANALYSERS ETC. SHALL BE POWERED FROM UPS SHALL BE POWERED FROM UPS COMPRISING OF 2 X 100 % CHARGER, 2 X COMPRISING OF 2 X 100 % CHARGER, 2 X 100 % INVERTER AND 1 X 100 % BATTERY.100 % INVERTER AND 1 X 100 % BATTERY.

• HEAVY DUTY Ni-Cd BATTERIES HAVE BEEN HEAVY DUTY Ni-Cd BATTERIES HAVE BEEN ENVISAGED FOR LONGER LIFE & LESSER ENVISAGED FOR LONGER LIFE & LESSER MAINTENANCEMAINTENANCE

CABLING & TERMINATIONCABLING & TERMINATION

• EXTENSIVE GROUPING OF SIGNALS BY EXTENSIVE GROUPING OF SIGNALS BY

LARGE SCALE USE OF JBs AT STRATEGIC LARGE SCALE USE OF JBs AT STRATEGIC

LOCATIONSLOCATIONS

• USE OF CABLES WITH HIGHER NO OF PAIRSUSE OF CABLES WITH HIGHER NO OF PAIRS

• USE OF MAXI-TERMI CONNECTION FOR USE OF MAXI-TERMI CONNECTION FOR

SYSTEM CABINETS, MARSHALLING PANELS SYSTEM CABINETS, MARSHALLING PANELS

& OUTGOING SIDE OF JBs, CJS BOXES etc.& OUTGOING SIDE OF JBs, CJS BOXES etc.

• USE OF PLUG-IN SOCKET AND CONNECTORS USE OF PLUG-IN SOCKET AND CONNECTORS

FOR TRANSMITTERS, SWITCHES, LS/TS etc.FOR TRANSMITTERS, SWITCHES, LS/TS etc.

IMPORTANT SG/TG RELATED C&I SYSTEMIMPORTANT SG/TG RELATED C&I SYSTEM

• FLAME MONITORING SYSTEMFLAME MONITORING SYSTEM• COAL FEEDER C&ICOAL FEEDER C&I• ELECTROMATIC SAFETY VALVESELECTROMATIC SAFETY VALVES• FURNACE TEMP PROBESFURNACE TEMP PROBES• ACCOUSTIC PYROMETER FOR FURNACE TEMP ACCOUSTIC PYROMETER FOR FURNACE TEMP

PROFILEPROFILE• BOILER FLAME ANALYSIS SYSTEMBOILER FLAME ANALYSIS SYSTEM• COAL BUNKER LEVEL MONITORING SYSTEMCOAL BUNKER LEVEL MONITORING SYSTEM• ELECTRONIC DRUM/SEPARATOR LEVEL MONITORING ELECTRONIC DRUM/SEPARATOR LEVEL MONITORING

SYSTEMSYSTEM• TURBINE SUPERVISORY SYSTEMTURBINE SUPERVISORY SYSTEM• TDBFP TURBINE SUPERVISORY SYSTEMTDBFP TURBINE SUPERVISORY SYSTEM

• IN PACKAGED SYSTEM, THESE ARE IN PACKAGED SYSTEM, THESE ARE UNDER SG & TG PACKAGES.UNDER SG & TG PACKAGES.

SCOPE OF SUPPLY OF C&I SYSTEMSCOPE OF SUPPLY OF C&I SYSTEM• DDCMIS (IN C&I PACKAGE, SG-TG C&I & DDCMIS (IN C&I PACKAGE, SG-TG C&I &

ASSOCIATED MMI etc. EXCLUDED)ASSOCIATED MMI etc. EXCLUDED)• OTHER SG/TG C&I (ONLY FOR TURN-KEY OTHER SG/TG C&I (ONLY FOR TURN-KEY

PACKAGE)PACKAGE)• MEASURING INSTRUMENTSMEASURING INSTRUMENTS• SWASSWAS• CONTROL DESK/PANELSCONTROL DESK/PANELS• ALARM ANNUNCIATIONALARM ANNUNCIATION• ELECTRIC POWER SUPPLYELECTRIC POWER SUPPLY• CONTROL VALVE AND ACTUATORS (ONLY FOR 500 CONTROL VALVE AND ACTUATORS (ONLY FOR 500

MW PROJECTS, BEING DELETED FROM C&I IN MW PROJECTS, BEING DELETED FROM C&I IN RECENT PROJECTS)RECENT PROJECTS)

• MAINTENANCE & CALIBRATION EQUIPMENTMAINTENANCE & CALIBRATION EQUIPMENT• INSTRUMENTATION CABLESINSTRUMENTATION CABLES• PROCESS CONNECTION & PIPINGPROCESS CONNECTION & PIPING• PA SYSTEMPA SYSTEM• OFF-SITE PLANT CONTROL SYSTEM (ONLY FOR OFF-SITE PLANT CONTROL SYSTEM (ONLY FOR

TURN-KEY PACKAGE, ELSE IN RESPECTIVE MECH. TURN-KEY PACKAGE, ELSE IN RESPECTIVE MECH. PKG)PKG)

OPERATION PHILOSOPHYOPERATION PHILOSOPHY

• CENTRALISED OPERATION OF MAIN PLANT THROUGH CENTRALISED OPERATION OF MAIN PLANT THROUGH OWS & LVSOWS & LVS

• OFF-SITE PLANTS TO BE CONTROLLED FROM THEIR OFF-SITE PLANTS TO BE CONTROLLED FROM THEIR LOCAL STATIONS WITH STATION-WIDE LAN DATA LINKLOCAL STATIONS WITH STATION-WIDE LAN DATA LINK

• MINIMUM BACKUP INSTRUMENTATION MINIMUM BACKUP INSTRUMENTATION (( ORIGINALLY ORIGINALLY CONSERVATIVE, NOW REDUCED. CRITERIA - CONSERVATIVE, NOW REDUCED. CRITERIA - HANDLING EMERGENCY & SAFE SHUT-DOWN)HANDLING EMERGENCY & SAFE SHUT-DOWN)

• GEOGRAPHICAL DISTRIBUTIONGEOGRAPHICAL DISTRIBUTION - - ALTHOUGH NOT ALTHOUGH NOT VERY USEFUL FOR POWER PLANTS AS COMPARED TO VERY USEFUL FOR POWER PLANTS AS COMPARED TO PROCESS/INDUSTRIESPROCESS/INDUSTRIES, , BEING ADOPTED FOR FEW BEING ADOPTED FOR FEW AREAS WHERE SIGNALS ARE CONCENTRATED AREAS WHERE SIGNALS ARE CONCENTRATED (REDUCTION OF CABLING, MUCH LESS ERECTION & (REDUCTION OF CABLING, MUCH LESS ERECTION & COMMISSIONING TIME)COMMISSIONING TIME)

REDUNDANCYREDUNDANCY• IN CONTROL SYSTEMIN CONTROL SYSTEM

– ORIGINALLY THE CONTROLLERSORIGINALLY THE CONTROLLERS– ALT-I - SINGLE LOOP NON-REDALT-I - SINGLE LOOP NON-RED– ALT-II- MULTI-LOOP REDUNDANTALT-II- MULTI-LOOP REDUNDANT

– NOW ALT-I ABOLISHED.NOW ALT-I ABOLISHED. NOW 2 X 100 % OR 2 OUT OF 3.NOW 2 X 100 % OR 2 OUT OF 3.

• I/O REDUNDANCY - CURRENT PROJECTS HAVE HIGH I/O REDUNDANCY - CURRENT PROJECTS HAVE HIGH LEVEL OF I/O & DRIVE CONTROL MODULES LEVEL OF I/O & DRIVE CONTROL MODULES REDUNDANCY DUE TO LOWERING OF BACK-UP AND REDUNDANCY DUE TO LOWERING OF BACK-UP AND INCREASE IN NO. OF CHANNELS. IN FUTURE INCREASE IN NO. OF CHANNELS. IN FUTURE PROJECTS, LIMITED TO SAFETY SYSTEMS AND CASES PROJECTS, LIMITED TO SAFETY SYSTEMS AND CASES WHERE SENSOR REDUNDANCY IS THERE.WHERE SENSOR REDUNDANCY IS THERE.

• DATA COMMUNICATION SYSTEM - 100 % REDUNDANTDATA COMMUNICATION SYSTEM - 100 % REDUNDANT

• MMIPISMMIPIS– - REDUNDANT SERVERS- REDUNDANT SERVERS– MULTIPLE OWS (PRESENTLY 10 NOS, BEING REDUCED TO 6 MULTIPLE OWS (PRESENTLY 10 NOS, BEING REDUCED TO 6

NOS.)NOS.)

DESIGN CRITERIADESIGN CRITERIA

• PROVENNESSPROVENNESS– SUPPLIER’S EXPERIENCESUPPLIER’S EXPERIENCE– SYSTEM EXPERIENCESYSTEM EXPERIENCE– PROVENNESS VS OBSOLESCENCEPROVENNESS VS OBSOLESCENCE

• RELIABILITY AVAILABILITYRELIABILITY AVAILABILITY– HARDWARE QUALITY (PUBLISHED MTBF etc.)HARDWARE QUALITY (PUBLISHED MTBF etc.)– CONFIGURATIONCONFIGURATION– REDUNDANCYREDUNDANCY– FAULT TOLERANCEFAULT TOLERANCE

• STANDARDISATION AND UNIFORMITY OF H/WSTANDARDISATION AND UNIFORMITY OF H/W– SAME SERIES & FAMILY OF H/W AS FAR AS POSSIBLESAME SERIES & FAMILY OF H/W AS FAR AS POSSIBLE– DIFFICULTIES BECAUSE OF PACKAGING CONCEPTS & DIFFICULTIES BECAUSE OF PACKAGING CONCEPTS &

RESPOSIBILITY CENTRE & INTERFACES (EVEN IN TURNKEY RESPOSIBILITY CENTRE & INTERFACES (EVEN IN TURNKEY PACKAGE)PACKAGE)

DESIGN CRITERIADESIGN CRITERIA

• OPERABILITYOPERABILITY– DESIGN CONCEPT - FAIL SAFE ETC.DESIGN CONCEPT - FAIL SAFE ETC.– FALSE TRIP VS SAFETYFALSE TRIP VS SAFETY– OPERATOR CONVENIENCE DURING NORMAL RUNNING & OPERATOR CONVENIENCE DURING NORMAL RUNNING &

EMERGENCYEMERGENCY– MANAGEMENT REPORTINGMANAGEMENT REPORTING

• MAINTAINBILITY MAINTAINBILITY – STANDARDISATION (AS INDICATED ABOVE)STANDARDISATION (AS INDICATED ABOVE)– MODULAR DESIGN AND EXPANDABILITYMODULAR DESIGN AND EXPANDABILITY– DIAGNOSTIC, FAULT IDENTIFICATION AND FAULT TOLERANCEDIAGNOSTIC, FAULT IDENTIFICATION AND FAULT TOLERANCE– GUARD AGAINST OBSOLESCENCEGUARD AGAINST OBSOLESCENCE– AVAILABILTY OF SPARESAVAILABILTY OF SPARES

• OTHER CRITERIAOTHER CRITERIA– UNIT OPERATION PHILOSOPHYUNIT OPERATION PHILOSOPHY– MARKET TRENDS AND EVOLUTION OF INFORMATION MARKET TRENDS AND EVOLUTION OF INFORMATION

TECHNOLOGYTECHNOLOGY– FEEDBACKS FROM EXISTING SYSTEMSFEEDBACKS FROM EXISTING SYSTEMS

plc and ddcmis

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