MAXDNA Overview and Case-study
Presented by:
ANOOP K.
DGM
O&M-C&I
NTPC Ramagundam
INTRODUCTION ARCHITECTURE FEATURES CONCLUSION
ROLE OF DCS IN POWER PLANT
INTRODUCTION ARCHITECTURE FEATURES CONCLUSION
M..A..X..D..N..A ?
MAX Metso Automation Max Controls, USA
DNA Dynamic Network of Applications
Supplier: BHEL Electronics Division, Bangalore
(Technical Collaboration Agreement with Metso)
DDCMIS Distributed Digital Control,
Monitoring & Information System
DCS Distributed Control System
INTRODUCTION ARCHITECTURE FEATURES CONCLUSION
STATE-OF-THE-ART TECHNOLOGY
• Comprehensive solutions for process automation
• Sequences and Interlocks for all Equipment
• Automatic process control using PID or advanced
control algorithms
• Integrates Subsystems and provides classified
information to the user
• Similar architecture can be reconfigured for a hydro
plant or nuclear plant
INTRODUCTION ARCHITECTURE FEATURES CONCLUSION
SYSTEM ARCHITECTURE
Plant information network
ENGINEER’S
maxSTATIONS
STATION
Redundant 100 Mbps maxNET
maxLINK
maxOPC
FIBRE OPTIC
LINK
REMOTE PROCESSING UNITS
PLANT SUB-SYSTEMS
REMOTE I/O
INTRODUCTION ARCHITECTURE FEATURES CONCLUSION
NETWORK ARCHITECTURE
103 processors,
21 workstations
8 processors
Domain-3 for
Common plant
22 Layer-2 switches, 4 workstations 22 Layer-2 switches,
3 Layer-3 switches 3 Layer-3 switches
103 processors,
21 workstations
INTRODUCTION ARCHITECTURE FEATURES CONCLUSION
SOFTWARE CONFIGURATION
MaxVUE MaxTOOLS MaxVUE MaxStorian Alarms Trend, Log,
Runtime Configuration graphic Editor History Data SOE Reports
Software Backplane
DPU’s in … … … DPU’s in External
MaxPanel MaxPanel PLC’s
with OPC
INTRODUCTION ARCHITECTURE FEATURES CONCLUSION
PANEL CONFIGURATION
Net-A
NETWORK
Net-B
DPU-P DPU-S
Redundant Common Redundant
I/O I/O I/O
PS, PT, RTD, Solenoid v/v, Relays, Pneumatic v/v, Motorized Actuators
INTRODUCTION ARCHITECTURE FEATURES CONCLUSION
MMI CONFIGURATION - LAN
From PLC Sub
Operator Large Video Engineer MaxStorian (trend, systems Perf. Analys.
Workstation Screen Workstation log, reports) Diagn. Opt.
OWS x6 LVS x5 EWS x3 MXS x2 OPC x2 PADO
Net-A
Net-B
Unit-3 LAN Printers
INTRODUCTION ARCHITECTURE FEATURES CONCLUSION
MMI CONFIGURATION - WAN
Other Dept HOD’s
Shift Charge (graphics of both
Engineer Station Head O&M Head
units)
CRT CRT CRT CRT x13
Network
U3
Switch
U4
Station WAN
From U-4 LAN
INTRODUCTION ARCHITECTURE FEATURES CONCLUSION
MMI CONFIGURATION - WAN
PC Stations (only Employee Contractor
Stage-I
reports/plant NTPC Offline Satellite Remote
Interface
database) WAN Commn Technical
Center
CRT x9 Merit Order
Rating Server
MOR Gateway PC x2
Net-A
Net-B
INTRODUCTION ARCHITECTURE FEATURES CONCLUSION
NETWORK CONFIGURATION
INTRODUCTION ARCHITECTURE FEATURES CONCLUSION
HARDWARE COMPONENTS
Hardware: Metso Design, Manufactured by BHEL
• Workstations: Operator, Engineer, MaxStorian,
Gateway, OPC
• Dual Network with 10/100/1000 Mbps
connectivity: Fast Ethernet Switches
• Distributed Processing Units: Located in CER
panels, active-standby redundancy
• Input/Output Modules: Located in CER panels,
redundant for critical I/O
INTRODUCTION ARCHITECTURE FEATURES CONCLUSION
POWER SUPPLY & GROUNDING
• 24 V DC for all panels – 2 sources
• System Supply & Field Supply – Dual
• 220 V DC for MFT, trip valves – 2 sources
• 110 V AC for nozzle valves – 2 sources
• Separate Grounding for signal & shield –
Electronic Earth Pit
INTRODUCTION ARCHITECTURE FEATURES CONCLUSION
TYPES OF I/O MODULES
• Analog Input (4-20 mA) – 1 fuse per module
• Analog Output (4-20 mA) – 1 fuse per module
• Digital Input (24 V) – 1 fuse per module
• Digital/Relay Output (24 V) – 1 fuse per output
• RTD Input (3-wire/4-wire)
• Thermocouple/ mV Input
• Bus Extender module – for Remote I/O
INTRODUCTION ARCHITECTURE FEATURES CONCLUSION
REDUNDANCY
MMI Level 11 fold (6 OWS, 5 LVS)
Network Level 2 fold (Net-A, Net-B)
Processor Level 2 fold (Active, Standby)
Input/Output Level 1 or 2 fold (2 for critical I/O)
Field Instrument Level 1/2/3 fold (as per design)
INTRODUCTION ARCHITECTURE FEATURES CONCLUSION
SOFTWARE TOOLS
Software: Metso Environment/Platform on Windows,
Logic and mimic displays developed by BHEL
• MAXVUE RUNTIME:
– Operation display/action screens
• MAXVUE EDITOR:
– Display modifications
– Online logic editing
• MAXDPU TOOLS:
– Offline Configuration
– DPU Downloading
INTRODUCTION ARCHITECTURE FEATURES CONCLUSION
TYPES OF LOGS / REPORTS
• Hourly / Shift / Daily Log – automatic
• Maintenance Log (for auxiliaries)
• Startup Log (Boiler/Turbine)
• Trip Log (all major equipment)
– event triggered
INTRODUCTION ARCHITECTURE FEATURES CONCLUSION
DISTRIBUTED PROCESSING UNIT
• Intel P-II 166 MHz Processor for control
• Motorola 68332 25 MHz Processor for I/O scan
• Windows CE Operating System
• Connects to maxNET Data Highway
• Object-Oriented Configuration
• Rack Mounted with Chassis
• 8 MB flash memory, 64 MB SDRAM
• Modulating Control, Logic, Data Acquisition
• Event Reporting to 1 msec Resolution
INTRODUCTION ARCHITECTURE FEATURES CONCLUSION
DPU STATUS MONITORING
INTRODUCTION ARCHITECTURE FEATURES CONCLUSION
MAXSTATION
• P-IV 2.4 GHz 512 MB RAM 40 GB
• Windows 2000 operating system
• Easily reconfigurable as OWS / EWS /
LVS / OPC / Link / Storian
• Software backplane based DCS
communication
INTRODUCTION ARCHITECTURE FEATURES CONCLUSION
ENGINEER STATION (3 per unit)
• Offline logic configuration through
maxDPU Tools Application
• Online Logic Configuration through
maxVue Editor or Point Browser
• Plant Operation through maxVue Runtime
• Time Synchronisation supervision of all
nodes
• Network Diagnostics and troubleshooting
through Internet Explorer Interface
• Remote Server for HOD workstations
• Virtual DPU Simulation Utility
INTRODUCTION ARCHITECTURE FEATURES CONCLUSION
MAXSTORIAN (2 per unit)
• Historical Data Collection and Archiving
Software for maxSTATION
• “Delta-Save” data storage maximizes
system data capacity
• Typical scan time : 1 sec, Special 100 ms
• Archival storage to CD/DVD
• Supports interface to plant-management
networks like ERP
• Provides data for performance analysis
and diagnostics system (PADO)
INTRODUCTION ARCHITECTURE FEATURES CONCLUSION
MAXOPC (2)
maxNET • Interface to external systems :
PLC networks (Cooling Tower,
Ash Handling Plant etc.) through
OPC Client Applications
• Supports multiple simultaneous
communication protocols
• Supports data transfer from other
systems and networks
Plant Sub-Systems • All data available to
maxSTATIONS
INTRODUCTION ARCHITECTURE FEATURES CONCLUSION
MAXLINK (2)
maxNET
• Interface to external systems :
Firefighting, Bentley TSI
• Interfaces data between
maxStorian and PADO through
OPC server application
Plant Sub-Systems
INTRODUCTION ARCHITECTURE FEATURES CONCLUSION
maxNET Communications
• Proven Industry Standard, Switched Fast Ethernet
• High speed (10/100/1000 Mbps) redundant network
• Multiple simultaneous communication
• Utilises intelligent switching
• Very few collisions occur. Traffic is never stopped
INTRODUCTION ARCHITECTURE FEATURES CONCLUSION
Ethernet Switch Configuration
INTRODUCTION ARCHITECTURE FEATURES CONCLUSION
MAXDNA BASED OPERATION
Complete Plant Operation & Monitoring:
• SG & SG Auxiliaries
• TG & TG Auxiliaries
• Station C&I – Balance of Plant
• FOPH (HFO, LDO pumps)
• CWPH
• DM Plant (Boiler fill pumps &
DM Make-up Pumps)
INTRODUCTION ARCHITECTURE FEATURES CONCLUSION
MONITORING OF OTHER SYSTEMS
• Compressor (IAC/PAC Operation Facility)
• LDO Unloading
• PTCW, PTDM, Cooling Tower
• Fire Detection, Fire WPH, Service WPH
• Ash Handling, AWRS, LWTP
• CPU Regeneration, DM Plant
• CHP, Stacker-Reclaimer, Mill Reject
• Air Conditioning
INTRODUCTION ARCHITECTURE FEATURES CONCLUSION
WHY PREFER MAXDNA ?
Operation Says:
• Controlling the plant is so simple ! You just click
the mouse to do any kind of operation
• I can perform any kind of operation from any
workstation or any Large Video Screen !
• I am able to start the CW pumps, situated so far
away, from main plant control room !
• There is a concept called Automatic Plant Startup
(APS) for synchronizing the unit from cold condition !
INTRODUCTION ARCHITECTURE FEATURES CONCLUSION
WHY PREFER MAXDNA ?
C&I Says:
• Maintenance cost is reduced a lot ! There are only
around 10 types of cards in more than 100 panels
• Communication is so fast ! The network
connectivity is happening at 10/100 Mbps
• Security is defined in 9 levels: there is no fear of
system getting corrupted by unauthorized persons !
• Simulating virtual environment for testing
configurations is possible !
• Troubleshooting is easier and faster !
INTRODUCTION ARCHITECTURE FEATURES CONCLUSION
WHY PREFER MAXDNA ?
Management Says:
• I have information at fingertips from my desk !
SOE, Trends, Logs, Reports …
• Integration of offsite systems with main plant is
possible, reducing manpower deployment
INTRODUCTION ARCHITECTURE FEATURES CASE-STUDY
UNIT-4 TRIP ANALYSIS dt. 20 Nov ‘06
Observations as per Log Book:
• CEP-B got unloaded and later tripped
• CEP-A also tripped after some time
• Unit Runback operated
• Top feeders tripped, bottom feeders unloaded
• Boiler tripped on flame failure
• Consequently unit tripped
INTRODUCTION ARCHITECTURE FEATURES CASE-STUDY
Sequence of events-p1
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Sequence of events-p2
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Sequence of events-p3
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Sequence of events-p4
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Sequence of events-p5
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Sequence of events-p6
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Sequence of events-p7
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CEP Trend-p1
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CEP Trend-p2
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CEP Trend-p3
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CEP Trend-p4
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CEP Trend-p5
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Deaerator Control Scheme
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Fuel Trend-p1
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Fuel Trend-p2
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Mill Trend-p1
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Mill Trend-p2
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UNIT-4 TRIP ANALYSIS
Conclusions:
• CEP-B got unloaded due to strainer choking
• CEP-A tripped due to manual intervention
• Loss of both CEPs made unit capability = 0
• Mills F,G,H tripped due to unit runback
• Mills B,C,D got unloaded in auto
• Mills unloading caused low PA flow after
outlet temp rise and HAG close
• As a result, flame failure occurred
INTRODUCTION ARCHITECTURE FEATURES CASE-STUDY
UNIT-4 TRIP ANALYSIS dt. 20 Nov ‘06
Corrective Actions:
• Auto lower limit for mills at 30Tph
• Auto lower limit for fuel master at 36%
• Sustaining PA flow ensured during hot air
gate / damper closing (interlock to open CAD
full)
INTRODUCTION ARCHITECTURE FEATURES CONCLUSION
TO SUM IT UP …
TECHNOLOGY IS GROWING
FAST, LET US TRY AND
CATCH UP WITH IT !
THANK YOU …QUESTIONS ?
