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An Overview
METSO AUTOMATION MAX CONTROLS
Key Learning
Overview of maxDNA control system
The maxDNA Plant Automation System (PAS) is the latest version of Distributed
control system developed by Metso Automation MAX Controls, US. maxDNA
works with the popular operating systems Microsoft Windows 2000/XP and
Windows CE, along with high-speed switched Ethernet (maxNET)
communications and Distributed Processing Units (DPUs), to give an open
architecture and reliable control system.
The maxDNA DDCMIS follows a multi-level hierarchy. The lowest or first level
interacts with the actual plant by acquiring the parameters/status, and issuing the
actuating signals/commands. This is done by the I/O modules. The second level
performs closed loop control and open loop control, which is accomplished
through execution of atomic blocks by DPU in maxDNA. The operator console or
the Operator’s Workstation (OWS), and the supervisory console or the Engineer’s
Workstation (EWS), are at the third level. At the highest level, called Enterprise
Management Network, engineers and managers have access to the entire system
database.
The system consists of the following components:
Sequence of Events
Each DPU can monitor up to 500 discrete inputs as a built-in Sequence-of-Events
(SOE) recorder. These inputs are scanned 1,000 times a second and state changes
are time stamped with 1 ms resolution and stored in the DPU's 10,000 event
buffer. Each input has a separately configurable digital filter for contact
debounce.
Comprehensive Alarming
Each alarm block identifies up to 16 alarm conditions as a digital status. This
permits sophisticated interlocking control strategies with all other DPU functions.
Each data block provides a wide range of data acquisition alarm features
including multi-level, rate-of-change, and repetitive delta alarms, adjustable
hysterisis, time delays, re-alarm, and auto-acknowledge features. All alarms are
time tagged by the DPU and placed in the 10,000-event buffer for de-queueing by
the maxSTATIONs.
Quality Coding
All data within the DPU is marked with a quality code in addition to the output
value. Four quality states are identified Good (0), Doubtful (1), Substitute (2) and
Bad (3). The quality code is propagated throughout the system to be included by
trend and archive data.
Timing
maxDPU4E time stamps process alarms and events based on its internal clock.
The DPU clock time is periodically updated through maxNET based on the stable
time source within one of the maxSTATIONs. For high stability an IRIG-B clock
receiver can be mounted directly on the DPU and connected via the third Ethernet
port.
Programming
Programming the DPU is done through the IEC 1131-3 toolset in maxTOOLS4E.
The following backup states are used to decide which DPU will remain or assume
control:
1. Fully Healthy or Healthy Enough (DPU ready):
• DPU has some I/O errors below threshold
• Net A and/or Net B functional (outage of one for >5 min persistence)
• DPU active but can’t hear backup
2. Some Errors (DPU would rather not run):
• I/O errors above threshold while some IO good
• Net A and/or Net B functional (outage of one for more than 5 minutes)
• Pulse Faults
• Time Errors
3. Serious Errors (DPU will only run if necessary):
• IOM Diagnostic errors
• Net A and Net B both non-functional
• Database out of date
• All I/O Bad
4. Fatal Errors (DPU cannot run regardless):
. DPU total failure
The maxPAC Input/Output System links the maxDNA DCS to real world process
control I/O. The DPUs and the I/O modules mount in an I/O chassis assembly with
a backplane to provide the I/O bus connection. The maxPAC I/O System uses the
Model APS Power Supply Assembly, which provides 11V dc power for DPUs and
I/O. Because each module is individually isolated, the chassis can be split to
provide both system power and loop power. Addresses must be set for each I/O
module using the rotary switches which permit 156 logical addresses.
maxPAC is a family of I/O modules and racks that offers the user space saving,
high density I/O that is designed and built to withstand the harsh electrical
environment found in power plants and other high current switching environments.
The I/O modules are constructed of glass epoxy multi-layer printed circuit cards
with gold plated contact surfaces that mate with gold plated connectors in the
backplane of the rack that supports the modules.
I/O Configuration Options
There are three ways to provide for redundancy of the I/O modules and the I/O
bus:
i) Shared
• 1 set of I/O modules
• 1 I/O bus
• 1 DPUs connected with backup cable and with I/O bus looped to both
Shared Configuration
ii) Mixed
• 3 sets of I/O modules (primary, secondary, and common)
• 3 I/O buses
• 1 DPUs connected with backup cable and with common and separate bus
Mixed Configuration
iii) Independent
• 1 sets of I/O modules (primary & secondary)
• 1 I/O buses (primary & secondary)
• 1 DPUs connected with backup cable, each with its own I/O bus and I/O
modules
Independent Configuration
I/O Bus
• 10 microsecond transfers
• 8-bit parallel asynchronous I/O bus
• Parity checks are performed on all I/O
• LSI bus interface circuitry for better reliability
• Check-before-execute control strategy for output signals
• Module address verification and multiple module detection checks
• Bus fault detection by automatic confirmation of input data on every
module
I/O signals
• Normal or common mode rejection (IEEE-171, ANSI c37.90)
• Common mode transients bypassed to chassis metal work
• All points optically or transformer-isolated from the I/O bus
• Channel-to-channel isolation allows series or parallel connections
• Logic state indication on the front panel for digital modules
List of Analog modules
History
maxSTORIAN Process History is a highly efficient and flexible data
collector/compression application that acquires user-specified information on a
periodic basis, checks for changes between sample periods, and stores the sampled
values on the 40GB RAID disk (Redundant Array of Inexpensive Disks). Users can
archive process history data to CD-ROMs (typically message prompts for download
at 80% of the disk capacity). The tool time-stamps data at the source whenever the
event or process variable changes.
maxLINKS
maxLINKS is an application software run on a maxSTATION providing 16-channel
multi-protocol connectivity between the maxDNA system and external devices. The
user can export and import critical process data to/from external subsystems of
electrical protection, fire protection, manufacturer’s PLCs, RTUs, turbine control
systems, precipitators, ash handling, sootblowers, water analysis, condensate
polishing, vibration measuring etc. The protocols supported include Modbus RTU,
AB, Conitel RTU, GE Mark V turbine control etc. A maxLINKS server has the
capability to interface with 8 systems, and can store upto 10,000 points. The functions
of maxLINKS are:
• Configuration of services, members and underlying layers (helper and
transport DLLs)
• Response to the SBP for Read/Write/Subscribe on the configured points
• Core libraries (Immediate data acquisition), Helper and transport libraries
maxOPC
maxOPC server and the configuration tools provide a secure, easily managed data
exchange interface to plant and enterprise management application software that must
acquire real-time information from the maxDNA plant automation system.
maxOPC server is based on OPC (OLE for Process Control), a leading industry
standard which defines a method of exchanging real-time automation data among PC
based clients using Microsoft operating systems. OLE stands for Object Linking &
Embedding, which means the ability to use different file or objects in a single
application through appropriate linking with their parent applications.
maxOPC can either read values directly from a DPU or use maxSTORIAN as a cache
data source providing higher capacity and faster performance with reduced system
loading. Additionally, when maxSTORIAN is used as the data source, it is typically
installed on the same workstation as the maxOPC server to reduce subscription
loading to DPUs.
Data access is configured through a maxOPC configuration server grid window and a
number of OPC configuration dialog boxes that prompt the user for tag names,
attributes, read/write privileges, and their on-data-change parameters in terms of SBP
delta, min/max times. This provides control over data access security and
performance loading.
Key Features
• Provides secure OPC client read/write data access to SBP data
• Supports demand writes and on-data-change and polling reads
• Access up to 300 values when direct access to maxDPU4E is used
• Access up to 2000 values maxSTORIAN is used as an exclusive cache source
Atomic blocks form the basis of all control or logic implementation. They are the
building blocks of the Closed Loop as well as Open Loop Control Systems (CLCS
and OLCS). They are software objects that encapsulate specific engineering
functionality, such as a PID, an Auto/Manual toggle switch or an AND gate. Atomic
Blocks are normally grouped into larger objects to encapsulate increased
functionality. Groups of atomic blocks constitute a custom function block object.
Custom function blocks can be applied in hierarchical identification levels (HID
levels) to form increasing levels of control system functionality. These HID levels
can then be assigned to a particular DPU. Atomic Blocks, buffers, and custom
function blocks are part of a DPMS (Distributed Point Management System), a
Microsoft Access-style database and client/server that composes a Distributed
Processing Unit (DPU). The DPMS manages its point database, provides master
scheduling, and executes the objects composing its database, among its various
functions.
Attributes
The data stored in an atomic block is organized as a set of attributes. All attributes
have subattributes like category, description, reference, attrwriteable, attrreadable
attrminval etc.
The attributes may be divided into the following categories:
General Foundation attributes required by all atomic blocks.
Inputs Values usually obtained by referencing another attribute.
Parameters Similar to inputs except that local value is used instead of reference.
They are predominantly used to configure the atomic block.
Outputs Values that are the result of the function or operation with which they
are associated. They are used to generate data for other atomic blocks.
Status Similar to outputs, they are predominantly used to monitor the atomic
blocks’ execution.
Custom User-defined attributes
Quality The behavior of atomic blocks may be based on the Quality of
its inputs.
Methods Methods direct an atomic block to perform a special function.
Eg. to change mode or target value, etc.
Commands Attributes that are used to receive commands from the HMI that will
initiate some action within the atomic blocks’ algorithm.
Reference Subscriptions
All inputs have several sub-attributes to represent their data. The local (default)
value and the reference pointer fields are configurable. The working value is
always retrieved by following the reference pointer. The following three cases
apply to input references:
1. When a reference pointer is not specified, the pointer by default points to the
local value.
2. Optimized subscriptions use the reference pointer to pick a value in the DPU
database (local memory) eliminating the need to subscribe to the Software
Backplane. This takes the same amount of processor time as retrieving a local
value.
3. Unoptimized subscriptions use the pointer to pick a value from a location,
which must be interpreted. These would include points outside the DPMS,
references to attributes of a different type, some status type attributes that are
not stored, and sub-attributes of input attributes. Values by unoptimized
subscriptions may not update every scan during periods of high DPU activity.
5.1 Self The knowledge gained in this training complements hand on working
experience gained during commissioning of unit 7 Ramagundam. Hand on
training exercises can be used to make proper procedure to implement certain
changes to DPUs and application software.
5.2 Section /’ Dept: The learning of this training can be applied to find solution to
plant problems and maxDNA is finding increasing applications in BHEL
supplied units..
5.3 Any other Deptt.of NTPC System knowledge will help in implementing
interfaces to mechanical and electrical systems as one is aware of the design
limits.
5.4 Company Level As BHEL is expected to supply and support maxDNA system
for boiler and turbine controls and balance of plant were required well into the
future, it is certain that the knowledge gained would be useful to iron out
problems at commissioning stage and for following better maintenance
practices.
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