MAXDNA Overview and Case-study

Presented by:
ANOOP K.
DGM
O&M-C&I
NTPC Ramagundam
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ROLE OF DCS IN POWER PLANT

Protections

Analysis Controls

DCS
Reports Operations

Alarms Monitoring
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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
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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
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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
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NETWORK ARCHITECTURE
103 processors,
Domain-1 for 21 workstations
1st Unit

8 processors

Network-I Domain-3 for Network-II

(Ethernet) Common plant (Ethernet)

22 Layer-2 switches, 4 workstations 22 Layer-2 switches,

3 Layer-3 switches 3 Layer-3 switches

Domain-2 for
2nd Unit 103 processors,
21 workstations
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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
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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
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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
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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
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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
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NETWORK CONFIGURATION
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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
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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
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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
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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)

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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
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TYPES OF LOGS / REPORTS

• Hourly / Shift / Daily Log – automatic

• Maintenance Log (for auxiliaries)
• Startup Log (Boiler/Turbine)
• Trip Log (all major equipment)
– event triggered
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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
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DPU STATUS MONITORING

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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
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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
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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)
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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
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MAXLINK (2)

maxNET

• Interface to external systems :

Firefighting, Bentley TSI
• Interfaces data between
maxStorian and PADO through
OPC server application

Plant Sub-Systems
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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
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Ethernet Switch Configuration

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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)
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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
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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 !
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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 !
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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
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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
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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
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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)
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TO SUM IT UP …

TECHNOLOGY IS GROWING
FAST, LET US TRY AND
CATCH UP WITH IT !

THANK YOU …QUESTIONS ?