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Morupule B

4 X150MW CFB
Power Station
I&C Training Material

DCS

DCS
ABB Symphony 800XA DCS system

DCS
General overview

With the increasing of unit capacity and parameter, the thermodynamic


system becomes more complicated, and the regular instrument and
independent control device and switches are not enough to process such
large amount of information and orders. Therefore, from 1960s, many
countries start to apply the electronic computer technology
to the
monitoring and control of power plant. The early computer control system
uses integrated computer control system to gather up the indication,
operation and control for hundreds of control circuit and thousands of
procedure variable on one computer, so it has a fatal disadvantage:
dangers are centralized.
Till 1970s, the manufactures all over the world produced different DCS
systems which are applied in the power plant widely.
1990s, almost all the power plants have adopted different DCS systems.

DCS

DCS refers to decentralized control system, which is a new control system


that combines computer technology, control technology, communication
technology and CRT technology to monitor, control, operate, and manage
the production process. The feature is decentralized control and integrated
management.
The monitor function and each control function can share information with
each other by data and information communication with network or busbar,
and can connect with the whole plant management computer by interfaces.
DCS is usually made up of integrated monitor and management parts
decentralized control part, and communication part. Among which, the
integrated monitor and management part is located in the central control
room, through which, the operator can use CRT to achieve Man-machine
interaction so to monitor, control, operate, and manage the operation
process

DCS
1. Layered architecture of DCS system
business management stage

4th stage
Production management stage
Procedure management stage
Final control stage
Continue process Batch process

3rd stage
2 stage
1 stage

decentralizing process On-site equipment

DCS
2. Composition of DCS system

DCS
3. Network of DCS system

DCS
4. Composition of local control cabinet

DCS
4. Composition of local control cabinet
5.
6.

3.

Main control unit: also called as main controller, usually is 1:1 redundancy
configuration, communicate with each intellect I/O module with fieldbus
Power module: the power module has unit modular structure, supply power
to control unit and local I/O module, form non-interference switching mode
of redundancy configuration. Common used:DC24V 48V. (during normal
working, each power module bears half of the load power)
Terminal module: the terminal module is working together with the regular
I/O module, achieve the connection of functional module and local signal .
Easy and convenient to set the station address with code switch. Antimixing pin is equipped for modules to prevent mis-installation for different
functional modules and base modules.

DCS
5. Common I/O module:
AI: Analogue input: receive DC420mA signal , or signal from TC or RTD on
site
AO: Analogue output: DC420mA signal
DI Digital quantity input: receive contact-type switch quantity signal on site
DO Digital quantity output: output passive contact-type switch quantity
signal

DCS
6. Composition of Basic
Controller

CPU :
Memory
Communication interface
Input/output channel
Other functional
components

Data highway

CPU

Memory

Communication interface

Internal bus
Other
components

memory

Communication interface

Production process

DCS
.CPU : It is the key part of basic control, the data processing and
control center of controller. The CPU functional components can do
calculation and program of information in the re-set cycle and
procedure, as well as operate, control and failure diagnosis to the
internal functional components of controller. In order to guarantee
the reliability of system, the CPU can adopt 1:1 redundancy
configuration.

.Memory It is used to store the standard algorithmic routine,


supervising program, self-diagnosis program of controller, and the
configuration of user, and basic controller database.

DCS
. Communication interface it mainly includes three parts: parallel
data input/output port (including the related buffering memory),
serial data receive/sent port (including receiver, sender, and
modem), and interface control circuit (including modem control
interface, receive/send controller, direct memory startup control
circuit, and synchronous inspection control)
. Input/output channel It has the interface function between the
basic controller and technical progress, which is achieved by the
high intellect I/O card.
. Other functional components In order to enlarge/expend the
function of basic controller and guarantee the safe and reliable
working of it, other functional components can be adopted, such as,
data input board, analogue display unit, diagnosis component,
switching components, and function expending components

DCS
7. Working process of DCS system
The procedure parameter from local sensor and transmitter will be
collected and processed by difference functional module, then
converted into digital signal which can be received by the computer. The
digital signal will be isolated by the optically coupled circuit and sent to
controller station via data bus
The basic controller in control station will output the control signal after
processing, based on the pre-set action laws, to control the production
process by actuating mechanism.
The procedure information will be sent to the operation station via data
highway in the control circuit. The operator can change the setting
value and control mode of each control circuit with the input device such
as keyboard and mouse, i. e. via the data highway, the control station
can receive the needed order and information sent from operation
station for optimizing the control.
For the procedure parameter not participating in the control, it will be
sent to the operation station via data highway to achieve display, alarm
and record.

DCS
8. Overview of network structure
Decentralized control system can realize the communication between
each internal unit through LAN.
Structure: bus type and ring network.
Common communication protocol: TCP/IP protocol
Profibus, CAN, ModBus, HART for local bus between basic controller
and I/O module.
Connect the different control unit with communication link, then it will
form the decentralized control system. The connection point in this
system is called as station.
The topology refers to the connection method between stations.
The topology forms: bus, ring, star, tree, and network.

DCS
9. transmission medium
. Twisted pair: refers to two twisted leading wire in together. There is
insulation medium between the two wires to control the clearance, so
the wire can meet the requirement for transmitting high frequency
signal. The twisted pair used for computer network is shielded two
conductor or four conductor type.
. Coaxial cable: used to transmitting electric signal with lower
frequency (several hundred HZ) . It has two types :75 and 50, the
former one is used to transmitting TV signal for CATV, the other one
is for baseband signal transmission in computer
. Optical fiber cable:
Principle: light can propagate in the glass.
Advantage: low transmission loss, wide transmission frequency
band, multi-way signal transmission
Application: communication field and computer network.

DCS
10.DCS system grounding/earthing

ABB 800XA DCS system


General overview of 800XA system
800XA intellect automation system from ABB.
Operation and configuration of Continuous control system and job-lot
control
2003
Industrial IT
System 800xA

Evolution
through
Enhancement

1996
1992
1987
1980

800XA DCS
Main function in the power plant
It can achieve the control function of following systems:
MCS: modulation control system
DAS: Data acquisition system
FSSS: Furnace safeguard supervisory system
SCS: sequence control system
DEH: digital electrohydraulic system
ECS: electric control system
BPS: bypass control system
Operator can monitor the production process through MMI
Display operation
real-time and historical trend
Alarm
Operation log
Periodical log
Event log
SOE log
Alarm log

800XA DCS
Two different hardware configuration:
BRC400 as main controllers : DEH,ETS
AC800M as main controller:
MCS,DAS,FSSS,SCS,ECS,BPS

800XA DCS:BCR-400
Operation Network Onet
Control Network Cnet
Control way C.W
I/O Expansion Bus X.B

1.DCS net structure

O net

C net
BRC400
NIS

C. W

NPM

I/O X.B

800XA DCS:BCR-400
2. Main component of local control cabinet

Mechanical installation component cabinet, module installation


unit, local terminal board
Data communication component control way, I/O expender
bus
Procedure control component communication module,
controller, I/O module
Local connection component terminal unit, pre-fabricated
cable
Module power-supply system

800XA DCS:BCR-400

800XA DCS:BCR-400
3. Introduction of main modules
.main controller BRC400

High performance, large capacity


procedure parameter processor
Adopt RISC microprocessor technology
32 bit industrial

800XA DCS:BCR-400
(2). Communication network module
INNIS01 INNPM11/12 module
network interface module INNIS01
network processing module (INNPM11/12)

800XA DCS:BCR-400

.I/O module
AI: Analogue input
AO: Analogue output
DI Digital quantity input
DO Digital quantity output

800XA DCS:BCR-400
(4). Power supply system

Power type supply this system:


System power supply
5VDC 15VDC
15VDC

Local power supply


24VDC 48VDC
125VDC

Equipment supplied with power


by this system
. HCU communication module
. HCU controller module
. HCU I/O module
. Local device connected to HCU

800XA DCS:BCR-400
. Feature of power supply system

Modular structure, 2N redundancy


Better power factor adjusting: 0.95
Replaceable power supply and fan
Power supply monitoring function
Be able to directly connect with 120/240VAC or 125VDC external
power supply
The double external power supply can be inputted in mixing under
2N redundancy structure
The load is borne by all the power supply modules together

800XA DCS:BCR-400
Main common used module
type

name

control

BRC400

General
module

SOE
module

description
CPU. 160MHz. 32bit

IMASI

16 way analogue input TC RTD

IMFEC

15 way analogue input :420mA

IMASO

14 way analogue output :420mA

IMDSI

16 way switch quantity input: 24VDC 48VDC 125VDC 120VAC

IMDSO

16 way switch quantity output: 24VDC 48VDC

IMDSM

8 way impulse input

IMRIO

Remote IO interface module

IMSOE

SOE server kit

IMSED

16 way event sequence digital input module

IMSET

16 way event sequence synchronization module

800XA DCS:BCR-400
type

name

IMFCS

DEH
module

IMHSS

description

Frequency computer
Frequency response range:1Hz----12.5kHz
Hydraulic servo module: redundancy LVDT input
Control output: control redundancy double-coil servo valve
Control current range:8--64mA
Status monitoring module: monitor the shaft vibration,
eccentricity, axial displacement

IMCMM

Electric
module

IMTAS

4 measurement channel, receive the


displacement, acceleration , speed signal
Turbine auto synchronization module
AC input generator/wire voltage 05 or 0150VAC

800XA DCS:AC800

800XA DCS:AC800

800XA DCS:AC800

COMPOSITION OF CONTROL CABINET

800XA DCS:AC800
HARDWARE
Status indication
Push button
RCU connector
Optical cable interface
Status indication

Outer battery slot

Communication interface

Baseplate

Processor: M861 AND TP830

SN
Ethernet address

800XA DCS:AC800
HARDWARE
Inner battery
CPU module

baseplate
slot
slot
Slot for power supply and signal
monitoring (connection:SS822)

800XA DCS:AC800

AC 800M

F(ault)

Red

Normal off

R(un)

Green

Normal (on)

P(ower)

Green

When Normal(on)

B(attery)

Green

Normal (on)

Tx

Yellow

Data transmission
(flash)

Rx

Yellow

Data transmission
(flash)

PRIM

Yellow

Main controller (on)

Dual

Yellow

When synchronization
(on)

800XA DCS:AC800
Redundancy CPU status indication
PRIM: yellow , DUAL:
flash
Primary is in service
Backup is in synchronization

DUAL : yellow, PRIM: off


Backup CPU is in service,

800XA DCS:AC800

TB840

S(tatus Green
)
Red

Green, in service
Red, fault

P(owo
k)

Green

Green, in service

Rx1

Yellow

Receive data from


upstream optical fiber
(flash)

Rx2

Yellow

Receive data from


downstream optical
fiber (flash)

ERx1

Yellow

Data communication
with I/O (A ) is normal
(flash)

ERx2

Yellow

Data communication
with I/O (B) is normal
(flash, ONLY FOR IO
REDUNDANCY
CONTION)

800XA DCS:AC800

800XA DCS:AC800

800XA DCS:AC800

I/O module

F(ault)

Red

Default (off)

R(un)

Green

Default (on)

W(arning)

Yellow Default (off)

Operation and maintenance of 800XA DSC

1. Environment requirement
(1) Temperature and moisture

The control room and electronic room should have air conditioner,
humidifying/de-humidifying device, and thermometer for detection and
maintenance use.

The technical standard requirement:


temperature: 15 30
humidity: 45 80
temperature changing ratio:5 /h

(2) Dust and vibration (in control room and electronic room )
Air particle density 0.3g/ , vibration magnitude0 5mm

(3) anti-static and anti-interference

The material used for control and electronic room should be anti-static
fire-retardant material. It is forbidden to use the equipment which can
generate interference (such as Mobil phone and walkie-talkie,) in the
electronic room during the operation of DCS

Operation and maintenance of 800XA DSC

2. Power supply system:


(1) Power supply mode

DCS has two ways of power supply, the normal power supply is
UPS power supply, and the other one is emergency power supply.
DCS is equipped with corresponding power module, making the
two ways of AC power supply is in redundancy and back up for
each other. The power module has auto, non-interference
switching mode, the switching speed 5ms
(2) Power supply index
. Voltage: AC 220V10
. Frequency: 50HZlHz ]
. waveform distortion<5
(3) Requirement on UPS

The UPS power supply should meet related requirement

The switching of working mode of UPS should not influence the


normal working of DCS.

THE Max. actual load of UPS should not exceed the 40% of rated
load.

Operation and maintenance of 800XA DSC

3. Operation and maintenance


. Operation of DCS
a.
b.
c.
d.
e.

DCS should be able to put into service reliably according t t0 to


unit requirement. During the operation of unit, the data cannot be
downloaded from DCS.
If there emergency condition and have to download, must apply
and issue DCS inspection and maintenance working application
sheet
Only the authorized staff in administrator level can operate the
system
The special DCS operation log should be formed for the C/I
discipline, to record the operation condition and abnormal
conditions, cause, handling process and method of DCS in detail.
The C/I staff should be familiar with the software and hardware
structure, and the configuration of each function; know well about
the various of defect and fault and the handling method; inspection
and maintenance of DCS during operation.

Operation and maintenance of 800XA DSC

. Once per day for the patrol inspection of DCS during


operation, including the following items
a.
b.

c.
d.

e.
f.

Check the temperature and humidity of electronic room


Check the fan condition of control cabinets and operation station,
make sure the filter of fan is clean and intact, the temperature inside
the cabinet meets the manufacturers requirement.
Check the status indication light for power module inside the cabinet,
make sure the power system is working normally with normal voltage.
Check the status indication light for communication module inside the
cabinet and operation station, make sure the communication of each
station is
Check the status indication light for control processing module inside
the, make sure the working and communication status is normal
Check the channel status indication light for I/O module inside the
cabinet, make sure the channel is working normally.

Operation and maintenance of 800XA DSC


g.
h.
i.
j.
k.

Check whether the redundancy modules have switching, if there


is switching, find out the cause, handle the failure, and make the
system back to normal.
Check the working condition of each part of DCS use the selfdiagnosis function of DSC
Check whether the equipment of operation station, engineer
station and each terminal ends are working normally
Check whether the clock in each operation and control station is
correct and synchronized
Check whether there is changing in the set level and
management scope of each operation station

Operation and maintenance of 800XA DSC

5. Daily maintenance of ABB 800XA DCS


1). Common equipment and tools for maintenance

Antistatic vacuum cleaner


Clean and soft cloth which is not easy to have wool falling-off.
Compressed air
Screwdriver specifically used for terminal
Sophisticated electronics cleanser
Natural hard brush
Specified nipper pliers
Precise multimeter
Signal generator
500V megameter

Operation and maintenance of 800XA DSC


2) Inspection and maintenance of DPU(Distributed Processing Unit)

Module inspection: the appearance is intact and complete; the setting


of switch, jumper, and other connector of the module is in accordance
with the instruction; clean the dust, dirt, oil, rust and other impurity on
the printed circuit board Power supply test: check the grade if input
voltage of power supply

Cooling fan inspection: the test run is normal, no abnormal sound

Cable inspection: check whether the connection cable and wire


between each station is correct and fixed.

Operation and maintenance of 800XA DSC

3). Daily maintenance of engineer and operation station


technical requirement:

System time: different stations must be in the same status and


indicates right;
System point directory: uniqueness and correctness;
Configuration diagrams can be normally imported, modified,
debugged, downloaded, and safely operated.
Point information: normal modification function.

equipment inspection:

Check and make sure the mainframe, monitor, keyboard, mouse,


printer, the communication cable are connected well
Power supply to each equipment is normal: 220VAC 50HZ
The engineer station is clean, temperature is 20 28
The function of keyboard and mouse is normal

Operation and maintenance of 800XA DSC

System condition inspection:

The graphics of monitor is stable, the icon is complete and in


good arrangement
The menu is complete, and function is normal
The status indication for each working station is normal
The communication between each station is normal

System basic function inspection:

The on-line / off-line modifying of configuration diagram and down


load function is normal
The dynamic display function is normal
The procedure monitor and control function is normal
Alarm management function is normal
System diagnosis function is normal
Data acquisition and tabling function is normal

Operation and maintenance of 800XA DSC

Maintenance of engineer station:

Change the passcode periodically and make good record


Backup the contents of the station periodically
Test the operation condition of network, if there is wrong
condition, correct it in time

Maintenance of operation station:

Clean periodically
Check the operation conditions and make record periodically
Check system time and make correction periodically
Check the working condition and printing quality of printer
periodically
Check whether the color and size of graphics in monitor is normal

Operation and maintenance of 800XA DSC

Periodical maintenance for peripheral equipment

Check the printer once a week, make sure the printing is good
and clean, spare paper is enough.
Check and make sure the keys on keyboard are flexible, no dead
key and key loss, the keyboard is clean, no dirt
Clean the mouse once a week, make sure it is flexible
Clean the computer desk once per day to make sure the whole
computer system is tidy without dust.