Management information system of the TPP power-generating unit

Customer: Novosibirsk CHPP-5 (OJSC “Novosibirskenergo”)he management information system (MIS) is based on the DCS¹ “Tornado-M” and designed for monitoring and control of some parameters of the 200 MW power-generating unit.

”...in 1998, the specialists of CJSC “Tornado Modular Systems” performed development, design, equipment setup and MIS adjustment of the power-generating unit No. 1 (N=200 MW). The system has been working reliably for three years. Since 1997 CJSC “Tornado Modular Systems” has been an APCS General developer of the power-generating unit No. 6 (N=200 MW). These projects are performed at the high sci-tech level using the most advanced technologies and industrial automation tools”.

Grecinger Sergey Alexandrovich
Deputy chief engineer of Novosibirsk CCHP-5
February 5, 2002.

Technological object

The control object is a 200 MW power-generating unit included in the TPE-214 boiler unit and the T-180 turbo unit. All non-operational measurement and registration (about 550 parameters) and control of the turbine part are included in scope of the system.

About the project

The system development was started in May 1998 with participation of JSC “Sibtekhenergo” – the leading technological organization in the Siberian region and “TeploElectroProekt” Novosibirsk Institute. The system adjustment was carried out by “Suneto” company. The contract covered all services of design, supply and APCS implementation at the object. The new APCS was scalable, which allowed carrying out its implementation in several stages. First, the information system was established and then the control functions were added to the system with direct participation of the station staff.

The APCS of the power-generating unit No. 1 has become a testing platform of running in real conditions of individual elements of the future full-scale APCS, which is being created at the power-generating unit No. 6 at present time.

In accordance with the assigned task, the APCS of the power-generating unit No. 1 is covered only some parameters of the turbo unit and the boiler unit. The hardware and solutions, which were used for creation of this system, complied with current requirements.

Design of the full-scale APCS of the power-generating unit No. 1 includes implementation of new software & hardware and architectural solutions specially designed for full-scale automation of the objects of this class.

Purpose of the system

The system is installed to replace some obsolete and worn out tools of automation of the existing monitoring and control system at the power-generating unit No. 1. The system is designed for monitoring and control of some technological equipment parameters of the power-generating unit by the operational staff. The central part of the APCS is a DCS. In addition to the DCS, the system consists of sensors, which are installed on the technological equipment. Operating control of the parameters covered by the system, is performed from a facility control desk. The system also gives necessary information on the state of the power-generating unit for the non-operational engineering and technical staff of the station.

System description

The system consists of the following components:

Controllers of the functional units

The CFUs provide connection of the cable communications from the sensors and conversion of analog signals into a digital form required for further software processing by the system.

The controllers perform the following functions:

Automated workstations (AWSs)

The AWSs of the system are based on a standard equipment, compatible with IBM PC. This choice was made due to service conditions of the facility control desk of the power-generating unit, close to the office ones and a low cost of service and support. Reliability of AWS has been increased by reduction of load on electric power supply of the computers.

Operator’s AWS

The power-generating unit operator’s AWS is formed by two IBM PC compatible computers. According to their functions, the computers are completely interchangeable.

The power-generating unit operator’s AWS is used for:

• registration and archiving of all updated data received from the controller in the operational registration archive;

• formation of information flow to the archive database set in database server;

• display of the parameters;

• representation of information in form of symbolic circuits, histograms, graphs and tables;

• performing solutions information & computing tasks (registration of emergency events, registration of deviation of the parameters, archiving, calculation of parameters for technical & economic index);

• representation of information for remote working stations using WEB-server resources.

APCS engineer’s AWS

APCS engineer’s AWS is installed in the non-operational circuit. In addition to similar opportunities of the operator’s AWS to provide operational information, APCS engineer’s AWS also provides preparation and issue of specialized reports of the archive database and allows carrying out analysis of any graphical information of any level of detail of the operational registration archive.

Database server

The database server is used for storage of data in the archive, representation of information on request and performance of calculating tasks.

Network organization

All components of the system are connected by Ethernet and Profibus local network. The Ethernet network topology is radial. The transfer medium is a twisted-pair cable, which connects all workstations of the operational circuit and controllers.

Radial connection is made using a network hub / switch-board. The controllers are connected by the field Profibus local network. The network is duplicate. Each controller performs the functions of the communication server, i.e. provides access from Ethernet network to stations connected to Profibus.

In case of failure of any element in any of the subnetworks, this structure still provides the access to all elements of the control system.

The network of the facility control desk provides the APCS connection to the existing station network. The upper level Ethernet network of the system is connected to the station LAN by an optic fiber line. Connection of the system LAN to the station Ethernet network is performed using the network “bridge” of the database server computer.

Cabinets of the controllers

The hardware of the controllers is placed in cabinets with double-sided service manufactured by “Rittal” company, which provide the IP55 level of protection. Each cabinet has Dims of 2000x800x800. Entry of the field cables is performed from below.

The cabinets include: controller, remote terminal units (RTUs), field interface units (FIUs) and necessary switching and electrically-powered equipment. Connection of the cable communications can be carried out directly from the sensors and actuators, including 220V signals, by passing by the special converters and the cabinets of intermediate terminal blocks.

Controller

The controller is designed as a VME crate of 6U format. The controller has a modular architecture. All controller modules are installed in the crate, where they are connected by the VME-bus line.

The main control element of a module of the VM642 central processing unit (CPU). The VMOD-4D medium-modules with MODPACK functional submodules are used as RTUs. Up to four functional sub-modules are installed on each medium-module. Two 50-pin connectors for connection of the four FIUs are available on the front panel of the VMOD-4D module. Up to ten medium-modules with forty functional submodules, which provide entry of various channels, can be installed on the controller crate.

Field Interface Units (FIUs)

The FIUs carry out connection of the field cables to the controller directly from the sensors without intermediate converters, aligners, etc. Conductor area of the field cable, which is connected to all FIU types from 0.8 to 2.5 mm.sq. The “WAGO” spring-loaded clamps are used for cable connection in FIU. The “WAGO” clamps provide a contact which is very reliable and non-sensitive to vibration.

1^ Distributed control system.