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ABB DDc
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STG Process Control System - Procontrol
Date: 14/03/2012
Liji P
C & I
2
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.
3
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
6
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
13
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Local Bus..
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Local Bus..
15
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Local Bus..
16
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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..
26
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Control Module..
27
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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
35
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
36
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
37
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