Application Solutions

Do programmable logic controllers offer better value than distributed control systems in this application?
A vis-a-vis comparison of sequential operations, boiler availability, system diagnostics, and alarming favors PLCs.

Two different microprocessor-based system platforms are currently available to handle a powerplants diverse system requirements - programmable logic controllers (PLCs) and distributed control systems (DCSs). To maximize system performance and minimize capital expenditures, plant engineers should consider the functional requirements of each boiler subsystem - combustion control, burner management, balance of plant, and data acquisition - before selecting a hardware platform. Leading manufacturers of both PLCs and DCSs have field-proven interfaces that support a seamless exchange of information between system platforms. Powerplants can select the most advantageous control platform for each boiler subsystem and still feature a centralized data-storage device or CRTbased operator console. Platform decisions made for one control subsystem should not unduly influence other subsystem platform decisions (see box). Powerplants retrofitting obsolete or troublesome burner management systems (BMSs) with microprocessor-based systems thus can choose between a PLC

(Fig. 1) or DCS platform. After considering the requirements of a BMS and evaluating the performance and cost of both platforms, it is suggested here that the PLC platform provides more value.

Sequential Operations
PLCs were originally designed as easy-toprogram, flexible, low-cost replacements for relay-based and solid-state hardwired discrete logic systems. DCSs were originally developed to replace electric analog control systems and analog manual/auto stations used for modulating control applications. Since burner management is implemented using discrete inputs and outputs (I/Os) and requires only sequential logic operations, hardware and programming costs for a PLC-based BMS are significantly less than for a similar DCSbased system. Typically, the installed cost of PLCs is 30-60% lower than DCS-based systems, depending on redundancy requirements and I/O partitioning schemes. Less hardware and software complexity results in lower maintenance and spare-part costs over the useful life of the system. These PLC advantages allow for the implementation of additional features that are usually cost-prohibitive or unavailable in a DCS platform. A well-partitioned system architecture and a detailed alarm Also, on further investigation, it can be shown that PLC processors are able to update I/O tables and cycle through sequential logic faster than DCS processors. Typical scan rates for 128 discrete I/Os is 2 ms for a PLC, 20 ms for a DCS. For a system architecture with remote I/O, the difference between DCS and PLC update times grows and the hardware price increases for the DCS platform.

Benefit: Real-Time Control, Communication and Visualization

management package are two critical features that can be cost-effectively incorporated into a PLC-based BMS.

pulverizer into a different processor limits the number of burners impacted by a processor failure. The partitioning of logic into multiple processors is cost-effective because the leading suppliers of PLCs manufacture a number of different processors for each product family. These processors range in memory size from 1 to 64K of words and support a discrete I/O capability of between 52 and 3072 points. DCS manufacturers do not offer the range of processor sizes, thus are not at a competitive price disadvantage. Redundant processors are used in deenergize-to-trip systems to eliminate the possibility of a single processor failure tripping the entire boiler. Failure of the processor that controls the master-fuel-trip (MFT) logic and the boiler common I/O will trip a unit off-line. To prevent this type of failure, the processor associated with the MFT logic and boiler common functions is backed up with a second hot processor. Remote I/O, a common feature with PLC platforms, is installed to reduce cable routing costs. Using remote I/O adapter modules to communicate with the master processor, I/O modules can be located next to the process equipment rather than in a centralized rack in or near the control room. BMSs that adhere to a true power-to-trip philosophy are particularly I/O intensive. Typically, two input signals are required to determine if a fuel valve is open or closed; two output signals are also required to open and close the valve. Thus, substantial savings in field wiring costs

can be realized if remote I/O adapters can locate the I/O modules closer to each burner firing level or pulverizer.

Boiler Availability
BMS architecture with a PLC can increase unit availability by minimizing the effects of a failed system component on overall boiler operations. I/O modules can be partitioned into functional groups, each of which is dedicated to a specific piece of process equipment. For example, the I/O modules associated with one or two burners are designated as a functional group. This functional grouping of modules assures that the failure of any single I/O module will only affect one or two of the boilers burners and will not jeopardize the entire units steam production. Functional grouping of I/O modules also simplifies programming and troubleshooting. The burner logic for a functional group is created only once, then copied for the remaining identical pieces of process equipment. I/O assignments, ladder logic, and wiring are identical for all similar functional groups. Because of the inexpensive hardware cost of PLCbased I/O modules, functional groups can be cost-effectively generated for burners, fans, feeders, and pulverizers. Partitioning of logic into multiple processors and the availability to implement redundant processors can also help to improve a boilers uptime. This is especially true for large boilers with multiple burner firing levels that operate on a de-energize-to-trip (failsafe) philosophy. Separating the logic and I/O associated with each firing level or

System Diagnostics, Alarms

A big advantage offered by microprocessor-based PLCs is their detailed diagnostic and comprehensive alarming capability. With proper programming, a BMS is able to help identify the location of a system hardware fault, provide first-out cause-of-trip alarm messages, indicate the cause of an attempted but restricted operator action, and identify any final-control-device failures. PLC processor speed in updating I/O tables and executing the ladder logic allows for timely capture of the following events: Startup diagnostic messages help enhance operator acceptance of a new BMS, especially if old benchboard controls are being replaced with new CRT-based stations. The messages indicate any permissives that are not satisfied when an operator attempts to initiate a desired sequence. For example, when an operator depresses a burner start pushbutton, the logic checks to see if all the burner permissives are satisfied. Any missing or dissatisfied permissive are displayed to the operator. Starting diagnostics are generally programmed for purge, opening of header valves (Fig. 2), pulverizer starts, and ignitor and burner light-off. First-out-cause-of-trip alarms identify to the operator the first input received by the system that initiated a shutdown. Armed with this information, maintenance technicians can significantly reduce the time it takes to diagnose the cause of a

trip, remedy the problem, and place the unit back on line after an unplanned shutdown or trip. Final control device alarms alert the operator to valve failures. All valves with limit switches controlled by the BMS are monitored by feedback inputs to verify that their position agrees with the state commanded by the PLC processor. Any valve not so verified is alarmed to the operator. System hardware alarms indicate I/O module, processor, and/or system communications failures. Alarm messages indicating module type that failed, its location in the system, and the exact input or output channel that failed (Fig. 3). With this type of detailed information, maintenance technicians can quickly identify and replace failed system components. The detailed hardware fault detection described in the last two items requires system I/Os in addition to those specified for the field devices. Although implementing detailed alarm management in a DCS is possible, it is considerably more expensive because of the higher hardware costs associated with DCS I/O modules.

system are abreast of the latest published standards, are experienced in the startup and operating of similar boilers, and are skilled system programmers. Good project support plus the correct platform help assure a safe, reliable system.

References
1 NFPA 85C Prevention of Furnace Explosions/Implosions in Multiple Burner Boiler-Furnaces, An American National Standard, 1991 ed, 85C-11 2 Ibid, 85C-15 3 Ibid, 85C-25

A final note
Safety and reliability of a BMS rest on the capabilities of system engineers. To gain full benefits of any hardware platform used to implement burner management, plant owners and operators must be assured that the engineers designing the

GMSE00-AP010B-EN-P July 2002 Supercedes Publication GMSE00-AP010A-EN-P September 2001

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