Bài giảng Introduction to DCS and DAS in thermal power station & recent trend of technology - Bùi Đăng Thanh
Presentation outline
Introduction to DCS and DAS in Thermal
DAS and DCS
Power Station & Recent Trend of Technology
DCS of ABB for Thermal Power Plant
DCS of Yokogawa for Thermal Power Plant
Recent Trend of Technology
Instrumentation and Control of Steam Turbine Power Plant
Dr. BUI Dang Thanh
Vice Directer
Institute for Control Engineering and Automation- ICEA
Hanoi University of Science and Technology
1 Dai Co Viet road, Hà Nôi, Viêt Nam
“Nothing can stop an idea when its time has come”
Victor Hugo
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2
Content
Introduction to DCS & DAS
History of Control Hardware
Advantages of Digital System
Computer Control Networks
DCS Elements
Part 1
DAS and DCS
Advantages of DCS/Objective of DCS/Benefits of DCS
Modes of Computer control
Utilization of DCS
DCS Vendors
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1
Introduction to DCS and DAS
History of Control Hardware
DCS – Distributed Control System
Pneumatic Implementation:
Collection of hardware and instrumentation necessary for implementing
Transmission: the signals transmitted pneumatically are
slow responding and susceptible to interference
control systems
Provide the infrastructure (platform) for implementing advanced control
Calculation: Mechanical computation devices must be
relatively simple and tend to wear out quickly.
algorithms
Electron analog implementation:
DAS- Data Acquisition System
Transmission: analog signals are susceptible to noise,
and signal quality degrades over long transmission line.
Selecting and building a DA&C (Data Acquisition and Control) system that
actually does what you want it to do requires some knowledge of electrical
and computer engineering.
Calculation: the type of computations possible with
electronic analog devices is still limited.
• Transducersand actuators
• Signal conditioning
• Data acquisition and control hardware
• Computer systems software
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History of Control Hardware
Advantages of Digital System
Digital Implementation:
Digital computers are more flexible because they are
programmable and no limitation to the complexity of the
computations it can carry out.
Transmission: Digital signals are far less sensitive
to noise.
Digital systems are more precise.
Calculation: The computational devices are digital
computers.
Digital system cost less to install and maintain
Digital data in electronic files can be printed out, displayed on
color terminals, stored in highly compressed form.
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2
Computer Control Networks
Computer Control Networks
PC Control:
Programmable Logic Controllers:
Display
Good for small processes
such as laboratory prototype
or pilot plants, where the
number of control loops is
relatively small
specialized for non-continuous systems
such as batch processes.
Main
Computer
It can be used when interlocks are required;
e.g., a flow control loop cannot be actuated
unless a pump has been turned on.
Final
control
element
Data
acquisition
PROCESS
During startup or shutdown of continuous
processes.
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Data Acquisition System- DAS
Data Acquisition System- DAS (Cont.)
A data acquisition system consists of many components that
are integrated to:
Data Acquisition System Block Diagram
.
.
Sense physical variables (use of transducers)
Condition the electrical signal to make it readable by an A/D
board
.
.
Convert the signal into a digital format acceptable by a
computer
Process, analyze, store, and display the acquired data with the
help of software
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3
Data Acquisition System- DAS (Cont.)
Distributed Control System- DCS
Most comprehensive
Data acquisition and control hardware generally
Supervisory (host)
Computer
performs one or more of the following functions:
Operator
Control
Panel
Main
Control
Computer
Operator
Control
Panel
Archival
Data
Storage
analog input,
analog output,
digital input,
Data highway
To other Processes
To other Processes
Local data acquisition and
control computers
Local
Computer
Local
Computer
Local
Computer
digital output and
counter/timer functions
Local Display
Local Display
PROCESS
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DCS Elements-1
DCS Elements-2
Data Acquisition and Field Control Unit: Digital (discrete) and
Batch Sequencing Unit: This unit controls
a timing counters, arbitrary function
generators, and internal logic.
analog I/O can be handle.
–
–
–
Controller modul
Input modul ( Analog :4-20mA, RTD, TC…; Digital:)
Output modul
Local Display: This device provides
analog display stations, and video display
for readout.
•
Analog output
Digital output
Bulk Memory Unit: This unit is used to
•
store and recall process data.
–
–
Power supply
Communication modul
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4
What is a DCS & PLC
DCS Elements-3
General Purpose Computer : This unit is programmed by a
customer or third party to perform optimization, advance control,
expert system, etc
In a control system there are three
elements:
.
measurement,
.
.
control algorithm;
final control element.
Central Operator Display: This unit typically contain several
consoles for operator communication with the system, and multiple
video color graphics display units
A PLC: Programmable Logic Controllerwas historically for machine control.
This means that it is primarily on/off control. Fast control loops, in the order
of milliseconds.
Data Highway : A serial digital data transmission link connecting all
other components in the system. It allow for redundant data highway
to reduce the risk of data loss
A DCS: DistributedControl System was historically for control of a process,
where there are many analogue variables: pressure, temperature, flow:
constantly changing.
Local area Network (LAN)
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What are the important features of a DCS?
DCS is the Centre of Information
Distributed means:
Management
Distributed Risk: Reliability is important as many components
are linked together. Redundancy is a method of distributing
the risk.
Operator
Load Dispatch
DCS
Controller
PLC
Distributed components: Controllers, Inputs and Outputs
(measuring and control signals)
Robust communication system to connect the components:
Auxilliary:
Coal Plant, Water Treatment
I/O, controllers, operator interface.
Field Signals
Boiler/Turbine
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5
Power Station Control
Pha Lai Architecture Diagram
Complex Process: many relationships between many variables,
Plant efficiency is related to how well the control is tuned,
The Control System must not be the limiting factor to achieve
efficiency,
Control must be robust to overcome plant problems, without a trip or
plant shutdown,
Availability of DCS must be almost 100% to achieve plant efficiency:
Redundancy to give reliability
Ease of use of DCS to look at data
Many Auxilliary Plants: often with PLC’s
21
22
Advantages of DCS
Objective of DCS
Access a large amount of current information from the data highway.
Monitoring trends of past process conditions.
This image cannot currently be displayed.
. Safe operation of plant
Readily install new on-line measurements together with local computers.
. Lowesr cost of generation
. Longest equipment life
. Minimum efficiency
Alternate quickly among standard control strategies and readjust
controller parameters in software.
A sight full engineer can use the flexibility of the framework to implement
his latest controller design ideas on the host computer.
. Energy conversation
Digital DCS systems are more flexible. Control algorithms can be
changed and control configuration can be modified without having
rewiring the system.
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6
Modes of Computer control
Benefits of DCS
signals from digital
computer
1. Manual
. High reliability
Local PID
controller
FC
2. Automatic
. Improved response time
• PID with local set point
3. Supervisory
. Improve operator interface to plant
Supervisory Control mode
• PID with remote set point
(supervisory)
Flow measurement
to computer
. Improve accessibility of plant data to engineering &
valve setting
from computer
managenment personals
4. Advanced
. Historical storage and retrieval system
Direct digital Control mode
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Utilization of DCS
Utilization of DCS
DCS vendor job:
installation
Implementation of advanced control:
Developed software for control algorithms, DMC,
Control Engineer Job:
Configuration
Aspen, etc.
Control-oriented programming language supplied by
the DCS vendors.
Built-in PID control:
How to Tune the PID control?
Self-developed programs using high-level
programming languages (Fortran, C++)
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DCS Vendors
• ABB
• Yokogawa
• Honeywell
• Siemen
• …
Part 2
DCS of ABB for Thermal Power Plant
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Content
The Benefit of Power Plant Control
Control system solutions
Power Plant Targets
Reduction of operational cost
– Manpower
– Fuel
Symphony System Components
Harmony System Terms
Performance optimization
Degree of automation
Advanced control solutions
Total plant DCS
Optimized redundancy
2 out of 3 protection
Detailed and fast diagnosis
hot replacement
Scalable system in Hardware and
Software
•
•
Harmony Power System and Packing
Harmony Rack I/O
– Maintenance cost
High availability
Harmony Rack Control & Communications
Engineering Tools – Composer
– Less trips by
protection
Optimized Startup and Operation
Human System Interface – OperateIT Process Portal
intervention
– No downtime by
DCS
•
•
Reduction of initial cost
Take part in power bidding
8
Tasks of Power Plant Control Systems
Tasks of Power Plant Control Systems
Operation, Measurement, Recording
Reliable power generation
Fast
on-line
capability
High
availability
Hazards
eliminated
Long
service life
High
safety
High
fficiency
Open loop control
Close loop control
Automation - Field to Board Room
The Symphony Components
Performer Series
The control system: Nerves and brains of the power plant
Information Processing Domain
Information-
management
Composer Series
Control Room
Equipment
Process Portal Series
Plant Operation Network
System Engineering, Operation
and Maintenance Tools
Human-System Interface
Analog control
Binary control
Protection
Switchgear
Control Network
Sensors
Harmony Series
Actuators
Signal and Logic
Processing Domain
Field Network
9
Symphony System Structure
The Symphony Components
Plant Network
Plant coordination for higher efficiency and performance
Information
Process Portal
Historian Server
Process Portal
Client
Process Portal
Configure Server
Composer
Clients
Management
Servers and Clients
Unit automation
OperationNetwork
Composer
Server and
Clients
Process Portal
ConnectivityServer and
Client
Process Portal
Redundant ConnectivityServer and Client
Boiler automation
Turbine automation
Burner
Mana-
gement
Fuel/
Air
Supply
Tempe-
rature
Control
Balance
of
Plant
Boiler
Protection
Turbine
Turbine
Turbine
Auxiliaries
Generator
ControlNetwork
Protection Control
One system for all application in the plant
Process I/O
Process I/O
Symphony
Harmony Control Unit
Symphony
Harmony Control Unit
Content
Harmony System Terms
Symphony System Components
Harmony System Terms
Harmony Power System and Packing
Harmony Rack I/O
Harmony Rack Control & Communications
Engineering Tools – Composer
Human System Interface – OperateIT Process Portal
Harmony Termination Unit
Harmony (Rack) Module
Harmony Cable
10
Harmony System Terms
Harmony System Terms
Cabinet: Cabinets are used to house the modules and terminations.
Module Mounting Unit (MMU): A MMU is a card cage that provides
electrical and communication support for Harmony modules. It provides
the housing, power connections and signals for communication
modules, controller, I/O modules.
Marshalling Cabinet
Termination Cabinet
System Cabinet
Harmony System Terms
Harmony System Terms
Power System: The power system provides +5VDC, +15VDC,
Control Network (C-Net): C-Net is a unidirectional, high-speed serial
data highway shared by all Symphony nodes. Redundant coaxial or
fiber optic communication cables connect individual nodes to form a
closed ring system. C-Net can support up to 250 nodes per ring and
250 rings per system. Multiple sub-rings link to the central ring through
local and remote interfaces that can be redundant.
-15VDC and +24VDC for Harmony system modules. It can also provide
+24VDC, +48VDC and +125VDC for field device I/O power.
Rear View
Front View
C-Net: Co-Axial Cable (Electrical)
Twin-Axial Cable (Electrical)
Fiber Optic (Ball of light passing through a glass tube)
11
Harmony System Terms
Harmony System Terms
Harmony Control Unit (HCU): A HCU usually consists of an entire
Harmony system cabinet containing power supplies, fans, HCU to C-
NET interface modules, controllers and I/O modules. Each HCU must
have its own unique address on the C-Net, the address could be from 1
to 250.
Node: Refer to Harmony Control Unit (HCU), Human System Interface
(PPB) and Computers connect to the C-Net.
Operation Network (O-Net): O-Net connects a number of computers to
share information or exchange data.Normally a Network Interface Card
(NIC) is used to allow the computer to connect and communicate to the
network.
C-Net to HCU Interface: Communication interface between the HCU
and the C-Net. It consists of two modules: INNIS11 Network Interface
Slave and INNPM12 Network Processing Module. Hardware
Redundancy is supported.
The NPM gathers data from the controller modules in its HCU and
transfer to the NIS. The NIS examines the data and transmits to the
specified destination on the C-Net. NIS also receives data sent by other
NIS in the system and sends this date to NPM for distribution to the
controller modules in the HCU.
Harmony System Terms
Harmony System Terms
C-Net to Computer Interface(ICI): Allow computer to access C-Net for
data acquisition, system configuration and process control. Engineering
workstation and PPB are connected to C-NET by using ICI.The ICI
includes INICI03 and INICI12.
C-Net to C-Net Local Interface(IIL): The IIL provides bidirectional
communication between a central C-Net and local satellite C-Net. The
INIIL02 Local Interface consists of two INNIS11 Network Interface Slave
modules and the INIIT03 Local Transfer Module. One of the INNIS11
modules operates on the central network side and the other operates
on the satellite network side. Communication between the central
network and the local satellite network is through cable connection to
the NTCL01 termination unit. The maximum distance between
termination units on the two communication networks is 45.8 meters
(150 feet). The IIL supports hardware redundancy.
The INICI03 interface consists of the INNIS11 Network Interface Module,
the INICT03A Computer Transfer Module, and the IMMPI01
Multifunction Processor Interface Module. The computer connects
through either an RS-232-C serial link at rates up to 19.2 kilobaud or
through a SCSI parallel port at rates up to 4MBytes/sec.
The INICI12 interface consists of the INNIS01 Network Interface
Module and the INICT12 Computer Transfer Module. The computer
connects through the RS-232-C serial link at rates up to 19.2 kilobaud.
12
Harmony System Terms
Harmony System Terms
Controlway: High speed, redundant, peer-to-peer communication link.
Used to transfer information between controllers, controllers and HCU
communication interface(NPM) modules. Cnet-to-Cnet interfaces also
use dedicated Controlway for redundancy communication.
Analog Control Station(IISAC01):
The SAC provides process loop control
and monitoring capabilities for a single
loop. It has manual control and bypass
capability for contact or 4 to 20mA
current outputs. Up to 64 SACs can be
connected to 1 controller. The
I/O Expand Bus: Also known as Slave Bus.Parallel communication bus
between the controller and its I/O slave modules.
communication link speed is 5k or 40k
baud.
Harmony System Terms
Harmony System Terms
Open Loop: An open loop control system is one where no function of
the controlled variable is used for automatic control of the system. It is
not a feedback control system.
Setpoint: A set point is the target value set for a process variable or
standard representing desired performance of the process variable.
Closed Loop: A closed loop control system is one in which the
controlled variable is measured and compared with a standard (setpoint)
representing the desired performance. Any deviation from the setpoint
is feedback into the control system to reduce the deviation.
Process Variable: A variable that is regulated by the control strategy of
a control device. The process cariable is also the controlled variable.
Control Output: Control output is the control system signal that
influences the operation of a final control element.
Station: A station allows the operator to adjust the setpoint in the
automatic mode(in closed-loop control) and the control output in manual
mode (open loop control).
Wild Variable: A wild variable is used as a reference for a control loop.
Sequential Control: Sequential control is logic or digital control of a
process using gating and timers. One sequential step must be
completed or timed out to permit the next sequential step.
13
Harmony System Terms
Symphony System Components
Harmony Packing
At a Glance
Harmony System Terms
The Harmony Control Unit
encloses all of the Harmony
Components
Harmony Power System and Packing
Harmony Rack I/O
Harmony Applications Platform
Host for the Harmony Controller and
Computer Communication Interface for
software applications
Harmony Rack Control & Communications
Engineering Tools – Composer
Harmony I/O
I/O subsystem for the Harmony Controllers
Harmony Power System
Provides power to Harmony electronics and
field devices
Human System Interface – OperateIT Process Portal
Harmony Power System
Harmony Power System
Power Supplies: P-HA-RPS-abcd0000
Highlights
a = 5 VDC Power Value b = 24 VDC Power Value,
•
•
Multi-Voltage DC Power System
c = 48 VDC Power Value d = 125 VDC Power Value
–
System Power (5, +/-15, & 24VDC)
–
Field Power (24, 48, & 125VDC)
5 & 15V (I) 24 V (I) 48 V (I)
125
V (I)
Versatility
RPS-1100
RPS-1110
RPS-1101
RPS-2100
RPS-2120
RPS-2101
RPS-3200
14 & 1
14 & 1
14 & 1
20 & 3
20 & 3
20 & 3
60 & 3
6
6
6
6
6
–
–
–
120 & 240 VAC, 125VDC Inputs
2N & N+1 Configurations
15 Pre-engineered Configurations
3
2.3
8.5
•
High Reliability
6
17
2.3
8.5
–
–
–
Load Sharing for 5 & 24V Outputs
MTBF > 400,000 Hrs
Front Access Maintenance
RPS-3220 * 60 & 3
17
17
RPS-3201 * 60 & 3
2.3
RPS-4000
100 & 8
RPS-0020
RPS-0001
RPS-0220
8.5
8.5
2.3
2.3
17
17
* 800 Watts Total
RPS-0201
RPS-0300
17 & 17
14
Harmony Rack I/O
At a Glance
Symphony System Components
Harmony System Terms
• Modular to meet varying
I/O requirements
Harmony Power System and packing
Harmony Rack I/O
• Used for A/D Conversion
and signal processing
Harmony Rack Control & Communications
Engineering Tools – Composer
• Configurable fail safe output modes
• Dedicated, secure, fast response
communication
Human System Interface – OperateIT Process Portal
to a single Controller pair
Harmony Rack I/O
Harmony Rack I/O
Termination Options
• Interface between field device
and I/O modules
• Packaging selections
– Low density, ring lug, 12 gauge
termination points
– MMU Mounted Terminations
– IS Barriers
– Rail mount terminations
– Interposing relays
15
Harmony Rack I/O
Harmony Rack I/O
Analog Input Modules
Cnet
Network
Interface
I/O
Module
Capabilities
Description
Termination
Unit
Rack Controllers
IMFEC12
•
•
Current (4-20mA)
•
15 independently
configured input
channels
NTAI05
Expander Bus
64 Addresses
Voltage (-10 – 10VDC)
x-bus
IMASI23
•
•
Current (4-20mA)
•
•
16 independently
configured input
channels
NTAI06
•••
High Level Voltage (-10 to
10 VDC)
ProgrammableA/D
resolution (16-24bit)
•
Low Level Voltage (-100 to
100 millivolt DC
•
•
Thermocouple
RTD
Process I/O
Harmony Rack I/O
Harmony Rack I/O
Analog Output and Control Loop Modules
Digital Input Modules
I/O
Module
Capabilities
Description
Termination
Unit
I/O
Module
Capabilities
Description
Termination
Unit
IMASO11
•
•
Current (4-20mA)
•
14 independently
configured channels
NTDI01
IMDSI22
•
•
•
•
24 VDC
48 VDC
125VDC
120 VAC
•
16 isolated channels NTDI01
Voltage (1 – 5VDC)
IMCIS22
Analog I/O
•
•
•
•
4 AI Channels
2 AO Channels
3 DI Channels
4 DO Channels
NTCS04
•
•
Current (4-20ma)
1-5VDC
IMDSI23
IMDSI24
•
•
24 VDC
•
•
16 isolated channels NTDI01
Digital Inputs
24VDC
Digital Outputs
•
48 VDC
16 isolated channels NTDI01
•
•
24VDC
48VDC
16
Harmony Rack I/O
Harmony Rack I/O
Digital Output Modules
Distributed Sequence of Events
I/O
Module
Capabilities
Description
I/O
Module
Capabilities
Description
Termination
Unit
INSEM01
Records, Stores, Processes Sequence of Events Master Module
IMDSO14
•
•
24 VDC
48 VDC
•
16 isolated channels NTDI01
and Manages up to 1500
SOE Points
NTDO02
INTKM02
•
Synchronizes the time for
inputs in HCUs
±1 ms resolution
•
•
Time Keeper Master Module
Supports IRIG-B receiver
6639890A2
(Standard
Relay Panel)
•
IMSET01
IMSED01
•
•
Time Stamps Inputs
Synchronizes Controller
with TKM
•
•
Sequence of Events Time Synch
Module
16 input channels
Time Stamps Inputs
•
•
Sequence of Events Digital Module
16 input channels
Content
Harmony Rack I/O
Distributed Sequence of Events Architecture
Symphony System Components
Harmony System Terms
Cnet
Harmony Power System and packing
Harmony Rack I/O
BRC
or
MFP
NIS
NIS
SEM
TKM
NPM
x-bus
Harmony Rack Control & Communications
Engineering Tools – Composer
SOE
Inputs
•••
SED
modules
SET
Human System Interface – OperateIT Process Portal
To Next HCU
NTST01
NTST01
Sattelite
IRIG-B
Clock
Time-synch
Twinax Cable
17
Harmony Control and Communications
Harmony Control and Communications
Redundant INFI-Net
250
x 250 Addresses
At a Glance
Overview
Cnet
Network
Interface
.
.
Multi loop, analog, sequential, batch
and advanced control processor
Supports multiple programming
environments to suit a variety of
application requirements
• Controller Modules
Rack Controllers
– IMMFP12, BRC100
Redundant Controlway
• Communication Modules
32 Addresses
– HCU Communications
x-bus
Expander Bus
64 Addresses
•
INNIS11, INNPM12
.
.
Backward compatible with older
generation MFC and MFP
Controllers
•••
– Computer Interface
•
INICI12, INICI03
On-Line, “hot” replacement
capability
– Bridges / Gateways
•
INIIL02, INIIR01
allows for ease of maintenance
Process I/O
.
.
“Self Boot-Up” support; non-volatile
memory
Redundant Support
Harmony Control and Communications
Harmony Control and Communications
Application Support
Highlights
• Standard Function Codes
Serial communication interface
• User Defined
Function Codes
to intelligent devices
• “C”/Basic Languages
Interfaces created in “C”
language and resident within
the controller
• Batch/Sequential
Control Languages
• Expert System
• Multi-Variable Control
Over 150 custom interfaces
have been created for PLC’s,
weigh scales, analyzers, etc.
Output layer
• Ladder Logic
fi()
Hidden
layer
wij
• Infi-Neural Net
Input layer
xi
18
Harmony Control and Communications
Harmony Control and Communications
Redundant INFI-Net
Control Network (Cnet)
250
x
250 Addresses
Function Code –The Building Blocks for Control Configuration
Cnet
.
.
High speed, high throughput and
high-security redundant highway
Network
Interface
Rack Controllers
Exception Reporting System
increases effective band width
and security
Redundant Controlway
32 Addresses
x-bus
.
.
Secure communications utilizing
CRC and message
acknowledgment
Expander Bus
64 Addresses
•••
Multiple (up to 250) Cnets and/or
older generation Plantloops can
be linked via Gateways
Process I/O
Harmony Control and Communications
Harmony Control and Communications
19
Harmony Control and Communications
Harmony Control and Communications
Cnet #1
Bridges and Gateways
Network
Interface
Bridge /
Gateway
Cnet to Cnet Remote
– INIIR01
– Support RS-232-C
Communication
• Transceiver
• Modem
Cnet #2
• Satellite Link
Cnet to Cnet Local
– INIIL02
Network
Interface
Bridge /
Gateway
– Direct Loop to Loop
Communication
Content
Harmony Control and Communications
Symphony System Components
Harmony System Terms
Harmony Power System and packing
Harmony Rack I/O
Harmony Rack Control & Communications
Engineering Tools – Composer
Human System Interface – OperateIT Process Portal
20
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