Introduction to Control Engineering at Power Plantsalkar/SEC510/Introduction... · 9 –Engineering Steps Dismantling and installation Page 10 • When the control system components

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Introduction to

Control Engineering

at Power Plants

Lesson 3


9 – Engineering StepsDetermination of configuration

Page 2

• Components of the new DCS

control system are determined

to comply with customer

technical requirements

• General configuration overview

is prepared

• Detailed network connection

plan is prepared

• Order codes of the

components are listed


9 – Engineering StepsConfiguration of 3rd party communication interface

Page 3

• Determination of the 3rd party

communication protocol

• Redundant or singular,

controlling station (master,

slave), network topology (point

to point, multipoint)

• Signal list of exchange signals

with communication

addresses, data volume

• Data format

• Physical layer of the

communication (RS232,

RS422, RS485, Ethernet, full

of half duplex, data Rate,

transmission distance)

• Type and length of the

communication cables

• Type and quantity of

converters, repeaters

• Definition of battery limit


9 – Engineering StepsFinalization of signal list

Page 4

1RB13P003 Hot reheat steam pressure FUM 230 AI 2 wire

1RB21P003 XQ01 IP bypass LH outlet pressure FUM 230 AI 4 wire

1RB21S003 IP bypass LH control valve FUM 280 AO CLC

1RB21S003 XQ01 IP bypass LH control valve position FUM 230 AI 2 wire

1RB21T003 XQ01 IP bypass LH outlet temperature FUM 230 AI 2 wire

1RB22P003 XQ01 IP bypass RH outlet pressure FUM 230 AI 4 wire

1RB22S003 IP bypass RH control valve FUM 280 AO CLC

1RB22S003 XQ01 IP bypass RH control valve position FUM 230 AI 2 wire

1RB22T003 XQ01 IP bypass RH outlet temperature FUM 230 AI 2 wire

1RM21S002 IP bypass LH spray control valve FUM 280 AO CLC

1RM22S002 IP bypass RH spray control valve FUM 280 AO CLC

1SA11P002 XQ01 Curtis stage steam pressure FUM 230 AI 4 wire

• The next step is the finalization

of signal list

• There are two approaches for

finalization of the signal list:

1) Process supplier prepares

the signal list for new built plants

2) DCS supplier prepares the

signals list for control system

refurbishment projects of existing

plants.


9 – Engineering StepsAssignment of signals to the modules

Page 5

• Assignment of signals to the

input output modules

• Process redundancy is taken

into consideration while

assignment


9 – Engineering StepsPlaning field connection and cabinet projects

Page 6

• Interconnection diagrams,

cable lists, cable routes,

connection typicals, terminal

plans, cabinet arrangement

drawings, circuit diagrams


9 – Engineering StepsDrawing HMI screens

Page 7

• Drawing HMI screens based

on P&I diagrams or draft

displays

• Linking dynamic elements with

function blocks


9 – Engineering StepsForming function diagrams

Page 8

• These diagrams or, in

other words, software

program runs in the

background when the

plant is in operation.

• The function blocks read the signals on the input

cards, process and send them to the output cards,

operator screens, alarm, report pages and archive.

• Function diagrams are formed based on the task

description documents.


9 – Engineering StepsProcurement, manufacturing and factory tests

Page 9

• The components of the control system are

procured. Cabinet components are installed in

cabinets during manufacturing in workshop.

• When the cabinet manufacturing is completed, it is

checked whether the mechanical structure and

electrical connections are completed according to

the project and standards. Similar conformity

checks are also made for equipment that are not

mounted in the cabinet.

• A factory test is performed with the optional

participation of the customer. The integrity,

suitability and functionality of the cabinets, external

components and documentation are checked once

again together with the customer.


9 – Engineering StepsDismantling and installation

Page 10

• When the control system components arrive at the

power plant, installation works can start. Prior to

that dismantling works are necessary for

refurbishment projects.

• Some of the tasks are:

Dismantling and mounting of the cabinets, cable

laying and termination, installation of field devices

and boxes, etc.


9 – Engineering StepsCommissioning steps

Page 11

Commissioning of

I&C configuration

Receiving inspection

and preparation of

commissioning for DCS

Switching on the DCSCommissioning of 3rd

party interfacesInstallation

DCS

Testing safety instrumented functions

(authority, adviser, customer)

Commissioning under operating conditions

(higher-level open-loop and closed-loop controls)

Process commissioning: Functions (individual/

drive /sub-loop/sub-group control, drive switch over)

Alarm optimization,

load cability test

Commissioning of process technology

Conducttrial run Acceptance

Cold function testing

System commissioning

Field signal and

equipment

testing

Supply power for

auxiliary and special

cabinets (Field)

- Continuously motor- Open loop and closed loop actuator, Solenoid valve control- Binary transducer- Analog measurement- Black Box

Field commissioning


10 - Engineering ToolsHW engineering tool

Page 12

Loop Drawings Cabinet Arrangement Symbol Library Document Query


10 - Engineering ToolsHW engineering tool (Cabinet arrangement)

Page 13


10 - Engineering ToolsHW engineering tool (Terminal table)

Page 14


10 - Engineering ToolsHW engineering tool (Loop drawing)

Page 15


10 - Engineering ToolsHW engineering tool (Outputs-table of contest)

Page 16


10 - Engineering ToolsHW engineering tool (Outputs-bus overview)

Page 17


10 - Engineering ToolsHW engineering tool (Outputs-power supply)

Page 18


10 - Engineering ToolsHW engineering tool (Outputs-power supply)

Page 19


10 - Engineering ToolsHW engineering tool (Outputs-cabinet arrangement)

Page 20


10 - Engineering ToolsHW engineering tool (Outputs-terminal table)

Page 21


10 - Engineering ToolsHW engineering tool (Outputs-part list)

Page 22


10 - Engineering ToolsHW engineering tool (Outputs-loop drawing)

Page 23

DCS cabinet MCC cabinet


10 - Engineering ToolsHW engineering tool (SW-HW tools navigation)

Page 24


10 - Engineering ToolsHW engineering tool (SW-HW tools navigation)

Page 25


10 - Engineering ToolsSW engineering tool (Login)

Page 26


10 - Engineering ToolsSW engineering tool (Workbench)

Page 27


10 - Engineering ToolsSW engineering tool (Workbench)

Page 28


10 - Engineering ToolsSW engineering tool (Diagram editor)

Page 29



Page 30



Page 31


10 - Engineering ToolsSW engineering tool (Plant display)

Page 32


10 - Engineering ToolsSW engineering tool (Trend display)

Page 33


10 - Engineering ToolsOperation view

Page 34

Project View

Trends

TAG-Browser

Alarm Display

Diagnostic View

ReportsPoint View

Parameter Set 2Parameter Set 1 Parameter Set 3

Function Diagram


Page 35

Thank you

Introduction to Control Engineering at Power Plantsalkar/SEC510/Introduction... · 9 –Engineering Steps Dismantling and installation Page 10 • When the control system components

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Introduction to Control Engineering at Power Plantsalkar/SEC510/Introduction... · 9 –Engineering Steps Dismantling and installation Page 10 • When the control system components