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Procontrol | Taylor MOD 30 and Mod 300

Distributed Control Systems for Industrial Automation

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PROCONTROL P

Analog and Binary Control, Boiler Protection, Turbine Control, Engineering, Diagnosis

DEABB 1261 E Procontrol P 100506.qxp 10.05.2006 09:23 Seite 2

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System configuration

PROCONTROL P –forward looking, innovative

PROCONTROL P is a digital process control systemwhich combines innovation and broad functionali-ty with established operational reliability.

Development of the PROCONTROL P power plantcontrol system is ongoing with the aim of furtherimproving• Cost-effectiveness• Functionality• Qualiy

PROCONTROL P`s renowed flexibility makes itsuitable for all applications from the smallest localcontrol to a comprehensive system for a largegeneration unit.Examples for the many successfultypes of application are heating power plants, refu-se incineration plants, industrial power plants, flue-gas scrubbing plants and water treatment plants.

PROCONTROL P is intended as a total system solu-tion which is open for the integration of existingsystems.It is thus especially suited for retrofittingand refurbishing existingplants.

The system solution PROCONTROL P includes:• I&C system• Engineering System• Erection,commissioning

service and training tools• Computer.based documentation

The exchange of data between the various compo-nents of the control and communication systemsta-kes place via a powerful fibre remote bus confo-ming to the FDDI standard.

The advantages of PROCONTROL P for the usersare:• Uniform overall systemfor all control functions• Simple straightforward structure and function

which is easy to handle and operate• Fully adaptable to the safety,availability and

commercial requirements of the process• Uncomplicated access to all data• System modification and expansion without

interaction with existing modules• Computer based documentation generation

and management• Maximized availability due to self-monitoring

and diagnostic functions• Forward-looking innovative system


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I&C Components

Stations:All-rounder or specialistA station accommodates the instrumentation andcontrol modules (I&C) and the coupling modulesfor man/ machine interface (MMI) and externalsystems (e.g.programmable logic controllers,pro-cess control systems etc.). The station bus couplerconnects the station to the remote bus. Theconnection to the remote bus is optional and thestation can operate in a stand-alone mode.

The main features of a station:Modular structurewith little basic equipment making the systemscalable, from the smallest control task to controlsystems for large-sized plants.• The control modules process the information

independently (multiprocessor system). Heart ofthe latest developments like the module 83SR52 is a 32bit MC68340 processor.

• Central units are not required to perform controlsystem tasks.

• I/O modules have their own microprocessorswhich makes signal acquisition and conditioning more efficient.

• Unrestricted availability of all measured processvariables in real-time.

• All data transferred within a station are also avail-able on the remote bus for other units in real-time. Conversely,every station has access to all the data on the remote bus. This principle of all data being universally available ensures absoluteflexibility with regard to modifications and system expansion. System maintenance is also simpler.

• The independent features of all units and mo-dules permit that they can be distributed bet-ween different stations to suit the requirements and possibilities on site.

Perfectly simple: In duplicatePROCONTROL P needs basically only two types ofmodules to perform all the signal conditioning andbinary and analog control tasks - the universalinput module and the binary and analog controlmodule. These two modules alone cover 80% ofall power plant control functions. The result is acontrol system with a clear structure, lower costsfor stocking spares and simpler maintenance.

The programmable universal input module in-cludes many features which were simply notavailable before. All types of transmitters used inpower plants can be connected to it.These include for example analog transmitterswith an impressed current in the range of 4-20 mAand binary transmitters with integrated NAMURinitiators (DIN 19234).

Racks within a station


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The programmable universal controller is used forall binary and analog control functions. The pro-gramming determines whether the controller hasto control a drive,a function group,a discrete regu-lation task or a complex processing function.

Standard interfaces:Milestones on the roadto open communicationInterfaces are available for connecting to othercontrol systems and automation devices.

Interfaces are needed wherever different systemprocesses such as programmable logic controllers(PLCs), process control systems, coupling PCs andmodems using different interfaces and communi-cation protocols are installed in a power plant.

As a consequence of having to couple many third-party systems to the PROCONTROL P bus over theyears, a whole range of interfaces covering a widerange of requirements is available.

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PROCONTROL P input module

The input module diagnoses the status of eachtransmitter,e.g. to detect loss of voltage, shortcircuit to ground,or wire breaks in process andtransmitter wiring. The results of the diagnosis aretransferred together with the value of the measuredvariable.

For each measured variable, the input module canmonitor up to four limit values. The permissiblelimits of a variable are therefore monitored wherethey should be, as part of the signal conditioningand preprocessing function.

The input module accurately linearizes signalsfrom non-linear transmitters such as thermo-couples. The values of the measured variables andthe type of transmitter can be freely programmedon-line for every input signal.


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The data transfer system:Open to ail suggestionsStations are connected to the remote bus with noreactive effects. The station bus and the remotebus form a single homogeneous communicationsystem and all process signal changes are availablein real-time on the station bus for every station.This unique feature of the system enables relatedfunctions such as signal acquisition, signal condi-tioning and binary and analog control to be eitherlocated together in one station (stand-alonesystem) or distributed between different stations(according to control functions). Therefore thereare no restrictions on the location of modules andany free slot can be used. This makes PROCON-TROL P,amongst other things,especially suitablefor refurbishing existing power plants.

Subsequent expansion of existing control systemscan be achieved simply without having to shut thesystem down and without encountering problemswith interaction between modules.

Remote busThe high-speed remote bus is based on the FDDI(Fiber Distributed Data Interface) token ringsystem according to ISO 9314. It is connected tothe station buses via remote bus coupling modules.Optical fiber cables are used for the actual connec-tions. These are firstly insensitive to electromagne-tic interference and secondly are suitable for maxi-mum distances of 2000 m between stations,at adata transfer rate of 100 Mbits/s. Maximum net-work sizes of up to 100 km can thus be achieved.

Data Transfer

The FDDI network is in the form of a double ring.The remote bus does not require any commoncentral components and is therefore capable ofrestructuring the system and maintaining commu-nication in the event of a fault such as the interrup-tion of one of the cables. In this way it fulfils thehighest demands with respect to availability.

Station busThe station bus is confined to a station and linksthe I/O and processing modules to the system.It comprises backplane p.c.b.s on all the racks,which are connected together.


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Control system diagnosis:Down to the smallest detailThe control diagnostic system (CDS) makes use ofthe special PROCONTROL P features, for example,every I/O modules has its own microprocessor andis therefore independent and able to monitor anddiagnose itself. These functions are active as soonas a module is inserted into its rack. Also all pro-cess data are available via the bus to all othersystem modules. Thus without having to be con-figured, CDS is able to recognize all the modulesin the system and display them graphically to-gether with their current statuses.

Every I/O module communicates its status data,type and location.From this information, CDSgenerates the control system graphically on thescreen and shows all the cabinets. Cabinets canbe individually identified and their states seenfrom their colors.

Diagnosis

Clicking on a cabinet "opens" its door and showsthe modules in their racks as in reality. Clicking asecond time displays the current contents of theregister in a module. As soon as a failure occursCDS guides the user by highlighting the cabinet,module and register concerned and by displayinga description of the cause. CDS also provides anon-line recommendation for corrective action.CDS includes a report function for analyzing con-trol system and process disturbance such as thecrossing of a limit value. Recorded data can befiltered for a period of time,components andtype disturbances.

CDS' clear graphic displays enable a comprehen-sive diagnosis down to the transmitter level with-out having to be specially configured. It is thus avaluable instrument for efficiently diagnosing andcorrecting disturbances.

Diagnosis Screen of CDS


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Many tasks - one system:Engineering, documentation and servicePROCONTROL EDS is the engineering,documen-tation and service system for the PROCONTROL Ppower plant control system. It improves theengineering,commissioning and maintenanceefficiency.

PROCONTROL EDS:More than just function block programmingThe engineering,documentation and service sy-stem PROCONTROL EDS is a tool for both internaland peripheral control components. It supportsthe engineering,commissioning and optimizationof control system functions. Since it is directlyconnected to the PROCONTROL P bus,EDS hasaccess to all the modules of the inner controlsystem throughout the plant. A network links EDSto the process operator station.

The main tasks performed by EDS are:• Data entry for the input and maintenance of

measurement and drive data• Generating and editing function charts for I&C

functions• Allocation of hardware (assignment of

functions) and downloading of programs• Debugging of function programs• Printing of function charts as necessary

EDS provides function-oriented as well as imple-mentation views. The power plant designationsystem e.g. the German KKS (tag name) is used toidentify engineering items;any addresses or otherspecific control system data are not required.A function is selected by its designation and dis-played graphically as a function chart on thescreen. The user executes any changes directly inthe function chart.

Computer generated documentation

Engineering, Documentation and Service for Power Plants

Exchange of PROCONTROL P modules during operation


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The function editor knows all the PROCONTROL Pfunction blocks and the rules for connecting them.When generating a function using EDS, the userselects a function block and connects it to otherfunction blocks by clicking on them with themouse!

The computer then automatically arranges func-tion blocks and their interconnections in the chartin relation to the syntax rules.

The data used by the function generator are alsoneeded to program the control modules and toconfigure the communication systems. This prin-ciple ensures absolute consistency between theactual programming of the control system, theconfiguration of the communication systems andthe associated documentation.

EDS automatically updates any other functioncharts and the connections to them which maybe concerned. All cross-references are there-forealways up-to-date and it is possible to navigatehorizontally through the function charts byclicking on inputs and outputs.

The same applies when making modifications,i.e.EDS automatically updates the other functioncharts. Wrong connections are detected and rejec-ted immediately an attempt is made to enter them.

On-line testing in function charts:Service made easyFunctions are commissioned with the aid of thedebugger. The desired function is called by its tagname (e.g.KKS) upon which it appears on thescreen as a function chart. It can be selected fromthe implementation-oriented view (cabinet, rack,modules) or from the function-oriented viewshowing the functions in their hierarchical relati-onship.

If the user wishes to observe the dynamic behaviorof a signal, he simply clicks on it in the functionchart. Because of the direct connection to thePROCONTROL P bus, EDS displays the values ofthe signals on-line in the function chart. It is notnecessary to specify measuring points.

The following supplementary data can be display-ed in the function charts:• Logical "0" or "1" for binary signals• Percentages for analog variables• Physical units for measurements• Signal error

Provision is also made for overwriting signals withvalues to be simulated for test purposes. All set-tings, limits and controller parameters in a func-tion chart can be selected and changed if neces-sary.


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PROCONTROL P Kesselschutz

Turbine control system:One of the familiesThe turbine control system comprisesPROCONTROL P programmable logic componentsand includes functions for:• Signal conditioning• Protection• Binary control• Analog control• Monitoring

Each of these functions has a clearly defined taskwhile running up or shutting down the turbineand while operating in the load control mode.

The measured variables are preprocessed in theelectronic input circuits of the binary and analogcontrol modules. PROCONTROL P componentshave also proved reliable for turbine protection.

As in the case with the other parts of the powerplant control system, the turbine control systemhas a hierarchical structure and a functionally dis-tributed layout. Control of the turbine is fully auto-matic.

Turbine Automation

The turbine regulator part of the steam turbinecontrol system is designed to control small tomedium-sized turbines mainly for industrial appli-cations (TURBOTURN) as well as the large reheaterturbines used by power utilities (TURBOTROL).

Highly adaptable standard modules enable a widerange of applications to be covered using standard,well-tried configurations. For example to raise theefficiency of power plants, it is becoming frequentpractice to tap off a part of the steam between IPand LP turbines for district heating. The associateddistrict heating controller can be implementedusing TURBOTURN and as an extension toTURBOTROL.

The TURBOMAX system is for monitoring thethermal status of turbine parts while starting andduring load changes ("load reserve computer").TURBOMAX optimizes turbine control time witha minimum of stress on the module.

Steam turbine


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PROCONTROL PF protection system:Programmed Iogic safetyThe purpose of the protection system is to reliablyprevent operating situations which represent ahazard for persons or plant. Safety-oriented controlsystems have the task of switching the process to asafe state before a potentially dangerous situationcan become critical. At the same time safety-orien-ted control technology ensures a high level of ope-rational availability of the facility in the best inte-rest of the plant user.

PROCONTROL PF is a three-channel stored-pro-gram protection system allowing the implementati-on of safety-oriented applications.

It includes standard test functions for periodicallytesting all the protection system components suchas:• Input signals• Input modules• Output signals• Tripping circuits

Boiler Protection

Even during testing, the protection system is in theactive state in order to be able to effect emergencytrips if need be.

The PROCONTROL FDDI bus provides non-inter-acting connection of PROCONTROL PF to all theplant control functions. All relevant data for archi-ving,diagnostics and operation are therefore avai-lable throughout the control system at all times.The use of field-proven modules of identical designrequires no additional interfacing efforts and facili-tates the diagnostic functions and maintenanceactivities.

Safety-relevant signals and circuits are generated,processed and tested within the protection system.The test routines for channels test the control func-tions without interfering with the control activitiesof the system.

PROCONTROL P boiler protection


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ABB AG Power Technology SystemsP.O. Box 10 03 5168128 MannheimGERMANYPhone: +49 (0) 6 21 381-30 00Fax: +49 (0) 6 21 381-26 45E-Mail: [email protected]: www.abb.com

Note:

We reserve the right to make technical changes or modify the contents of this documentwithout prior notice. With regard to purchase orders, the agreed particulars shall prevail.ABB does not accept any responsibility whatsoever for potential errors or possible lack ofinformation in this document.

We reserve all rights in this document and in the subject matter and illustrations containedtherein. Any reproduction - in whole or in parts - is forbidden without ABB's prior writtenconsent.

Copyright© 2006 ABBAll rights reserved

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Documents

Advant 800xA | Advant OS | ailey Infi 90 ailey Net 90 ... modules (I&C) ... (MMI) and external systems (e.g.programmable logic controllers,pro- ... with little basic equipment making