SYSTEM DESIGN

PHILOSOPHY FOR DDC SYSTEM

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01 OF 15

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: SYSTEM DESIGN PHILOSOPHY FOR

DDC SYSTEM

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CUSTOMER : M/s MONNET POWER COMPANY LTD.

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PROJECT

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| 2X525 MW MALIBRAHMANI TPS'

ANGUL,ORISSA.
DEVELOPMENT CONSLJLT;NTS
PRIVATE LIMITED
Reviewed only for general conformance
contract drawings and specifications.
Contractor to be responiible for any errors

and

fulfillment of detailed requirements ol cont)

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APPROVED BY :

MANIK NAIYA
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415/ MPCL/ 001

SYSTEM DESIGN PHILOSOPHY
FOR DDC SYSTEM

REV. NO. 02

PAGE 02 ()r'15

I
REVISION HISTORY SHEET
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SYSTEM DESIGN PHILOSOPHY

r.OR DDC SYSTEM

415i MPCL/ 001

REV. NO. 02

PAGE
1.0

03

OT 15

INTRODUCTION:

This document describes the design philosophy for DDC system based on maxDNA hardware
to be supplied to 2x525 Malibrahmani TPS,Angul,Orissa Project. The basis for this document
is the contract document and maxPAC hardware manuals. This document covers design of
SG/TG/Station C&I systems.
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2.0 CONFIGURATION
The configuration ofDDC system is as per the project configuration diagram and the details of
function grouping of SG/TG & BOP systems are as per the Partitioning / Controller Grouping
document.

The DCS is partitioned into Functional Group Units @GU) which are automation islands
responsible for control and monitoring of specified plant area. The FGUs communicate with
the maxSTATIONS and among themselves through data highway maxNET. The data highway
is formed through intelligent Ethemet switches. The FGUs communicate with the switches at
100 MBPS and the switches communicate among themselves at 100 MBPS. The data highway
is redundant with two lines designated as Line A and Line B. All the FGUs, maxSTATIONS
connect to the maxNET with redundant cormections.
The signals from/tq the field and are interfaced through Input/output modules in the FGUs.
The control logic reiides in the DPU. I/O modules and DPU communicate through the
backplane IiO bus. DPUs in FGUs are redundant. For VOs, redundancy is provided as per
specification requirement. FOPH controls are standalone system with its own DPU and MMI
and placed in FOPH control room. Remote I/O cabinets are housed in- the CWP area for
acquiring the I/os for the cwP system. The controllers for cwP system will be in the main
control room (CCR).

Unit Control Board (UCB) and Electrical Control Board (ECB) house pushbuttons and
indications for manual control of some critical drives,breakers. These are interfaced to the
DCS via VO modules. The annunciator logic will be realized in DDCMIS.
system input is connected to a pair of IRIG-B compatible DPUs
pair synchronizes all the other stations.

A master clock

This DPU

For non-DDC equipment time synchronization signals shall be taken directly from Master
Clock panel where ever it is required.
Interposing relays are provided for energizing the drives from DCS, wherever required.

The FGU panels

are powered by tedundant supply from UPS system.

SYSTEM DESIGN PHILOSOPHY

FORDDC SYSTEM

415/ MPCL/ 001

REV. NO. 02

PAGE

04

OF 15

2.1 Function Group Unit (FGU)

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will perform the firnctions of

data acquisition, protection and interlock, Closed loop

controls as required by the function group.
Each FGU consists of Distributed Processing unit (DPU), InpuU output modules and power
supplies. The modules are housed in racks and are connected through back plane bus. The
FGU is housed in freestanding panels. The panels also house terminal blocks to accept field
connections. FGU is designed to operate at 50 deg C and 95Yo RH. However, it is
recommended that these are placed in controlled environment for long and reliable operalion.
The FGU is connected to the Data highway by 100 Mbps Ethemet cable. It connects to both
the Data highways.

FGU

2.1.1 Input and Output Modules

The Input and Output modules connect the process variables and controllable end elements of
the plant. Depending on the type of signal to be processed the following tJpe of modules are
used:
a.

Digital Input Module for 24 V DC contact interrogation

b. Digital Output Module

Analog Input Module for 4-20 mA

Analog Inpui Module for 3-Wire / 4-wire RTD
e. Analog Input Module for Voltage
Analog Input module for T/C
Analog Output Module for 4-20 mA
h. Bus Extension Module
c.

d.

f.

roP 330
IOP 351
roP 301/ roP 302
roP 303
IOP 305
IOP304
IOP 320/IOP 321
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The I/O bus is a parallel backplane bus. The I/O modules plug on to the VO bus on the back
plane PCB. The DPUs access the VOs via the bus. This bus is extended to other racks through
inter rack extension cable.

Field contacts are interrogated at 24Y DC by a separate power supply, which is isolated from
the system power supply. Transmitters are powered through the module and each channel is
protected by a solid-state fuse. The I/Os are distributed functionally in the FGU.

SYSTEM DESIGN PHILOSOPHY

FORDDC SYSTEM

415/ MPCL/ 001

PAGE

05 0r'15

2.1.2 Distributed Processing Unit

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The Distributed Processing Unit maxDPU4F is a 32-bit multifunction controller and data
acquisition processor that executes control algorithms and sequence logic. It also performs
data acquisition and sequential events processing time tagged to mS resolution, for
identified signals.

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FGUs consist of a redundant pair of DPUs except for the MFT channels (MFT1,2,3)
which are configured in 2 out of 3 configuration. Each DPU of the redundant pair connects
to the redundant Data highway (Line A,/Line B) separately. The DPUs reside directly on the
Data highway without the need for servers. The connection is through a 100 Mbps Ethemet.

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Redundant pair of DPUs ensures that in case of an enor the control is automatically
transferred from Primary DPU to the secondary DPU. Any of the DPUs can be designated as
primary through configuration. The transfer is bumpless and does not affect the process.
Non-volatile FLASH memory maintains the control strategy conflguration during power
intemrptions .

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built into the DPU, which allows execution time classes

of 20-100mS (Critical), 100-500mS (High) and 500mS Qrlormal) to suit the process
requirement. Each. loop can be defined to be in any of the above classes. The time for each
class can be set withln the specified limits in steps of 20mS. Further each atom in the loop
can be programmed to be in one of the classes. However the loop execution times will be as
speed processing system is

per specification requirement.

comprehensive set of diagnostics is performed on a continuous bisis, which inctude
Check sums, Memory tests, Network RAM tests, VO bus tests, Power and Battery tests etc.

regarding the operation of DPU is kept in DPU memory, which include tag
names, descriptions, tuning constants, alarm limits etc. In addition all control configuration
data is located in DPU. Hence it is ensured that configuration is always current and what is
observed is the one, which is installed.

All information

The DPU can access any exposed data stored anywhere in the connected system through
software backplane installed in a1l the connected systems. Peer-to-Peer transfers are rapid
and transparent without independent transfer agent. The Software backplane is based on the
subscription services where data is transmitted on detection of changes.

415/ MPCL/ 001

SYSTEM DESIGNPIIIOSPHY
FOR DDC CONTROLS

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REV. NO. 02

PAGE 06 OF 15

Power Supply

The FGU panels are powered by redundant 24y DC derived from redundant feeders of 240V
AC UPS system through AC/DC converters. The power supply for the field instruments is
provided through sepaiate AC/DC converters housed in the panel. This ensures isolation
tetween System supply and field supply. Distribution of power supply is realized within the
panel.
The system and the interrogation supply to individual racks are distributed to the racks. Each
rack has provision for accepting system power supply, which is 24V DC and
interrogation/Transmitter power supply which is also 24V DC. The interrogation voltage is
routed-th,rough the input cards for powering the field instruments. The Fault of AC/DC
converters are monitored in DCS through binary input module in each FGU'

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The maxNET is the network and the middleware that allows for functional distribution of
system. It interconnects the FGUs, maxSTATIONs, and printers. The maxNET is redundant.
Ii is a high speed data highway and ensures that all stations have unlimited access without
delay and without the need for haffic director. The maxNET is based on switched Fast
Ethemet Standard and is full duplex. It uses intelligent switches and supports multiple
communication. It avoids collisions.

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The number of switches for DPUs depends on the number of DPUs for each system. The
switches are fully redundant and each DPU connects to both lines A and B. Similarly, each
maxSTATION connects to both the lines through switches.
The speed of Ethemet between DPUs and switch is 100Mbps full duplex. The speed between
any pair of switches is 1OOMbps full duplex.

SYSTEM DESIGN PIIILOSOPHY

FOR DDC SYSTEM

415/ MPCL/ 001

PAGE

07 OF 15

3.0 Hardware Design

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3.1 The following are considered for hardware design in order to meet the control
requirements

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which are configured in 2 out of3 configuration..

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with odd address is secondary.

c. Each DPU resides in different racks. It plugs on to the back plane VO bus.
d. Number of racks are provided for housing VO modules, each rack consisting

ofVO

back plane bus. The racks are interconnected with cables.

e.

The bus is terminated using bus termination module'

f.

Terminal blocks with cage clamp type connections are provided at the back of the

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rack, for riccepting field connections on one side and connect to the module on the
other side. All cabling ofsignals in the panels is done by 0.5 sqmm cables

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The DPUs are designated as primary or secondary depending on the address set. At

start up, the processor with even address always becomes primary and the other

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Each FGU has a redundant pair of DPUs except for MFT channels (MFTI,2,3)

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Each FGU is designed as single or suite of panels depending on the quantity of

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hardware to be housed.

h.

Each panel ofthe FGU is provided with cooling fans.

i.

For interfacing output commands to binary drives separate interposing relays housed

in MCC/SWGR will be used.

j.

Refer OGA for list of panels and other construction details.

k.

Shield bus is provided for termination ofshields ofincoming shielded cables.

l.

Required cable channels are provided in the panel for routing the field cables within
the panels upto the terminal blocks.

415/ MPCL/ 001

SYSTEM DESIGN PHILOSOPHY

FORDDC SYSTEM

REV. NO. 02

PAGE

A4-10

08

OF 15

3.2 Signal connection

a.Multiplemeasurementsforthesameserviceusedforcontrolareconnectedtodifferent

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inPut modules.

Drive signals based on drive control philosophy document

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Wherever aPPlicable.

c. All control related signals for a FGU is connected

in the same FGU' Information

related signals can be in different FGU'

d.

as followed in
Redundancy is achieved through "limb redundancy "concept
point 3'2 (b) above'
maxDNA system for both inputs and outputs as per

e.Themaximumnumberofdrivestobeimplementedinonesetofredundantoutput
module shall be limited to six'

SYSTEM DESIGN PHILOSOPHY

FORDDC SYSTEM

41s/ MPCL/ 001

PAGE

ad-10

09

OF 15

3.3 RedundancY

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Redundant processors are housed in separate racks'

Srrt.. po*.. ,upply, field power supply are all 1 :1 redundant'

a.

the switches of line A and Line B of maxNET

VO redundancy will be as per 3.2 above'

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3.4 Spares
provided unwired
10% of installed VO modules as spare will be
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on overall basis .

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(ii)

10% spare channels in VO modules will be provided

systemwired up to TBs on overall basis'

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10% wired in usable space on overall basis'

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to implement
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4.0 Application Software:
4.1 Control Software:

Functional Group Units' The soft-ware

Control Software is programmed in the DPUs of the
blocks designed
i, a"rig*a ,ti"g standid Atomic blocks of maxDNA system and custbm
blocks. The
Atomic
of Standard
;r-;;;-&. .oniot purpor". Reier maxoocS for details
together is known as DPU
,ot.i*e una tfr" related trardware configuration and the Database
also consists of
.""frg*"ii"" and is stored in a file t-uttta 'OptXeUE'4f ' ' This file
custom blocks.

TheDPUconfigurationsofalltheDPUsareavailableintheEngineeringStation.Thesecan
be downloaded into the DPUs via the maxNET'

requirements:
Application Software is designed for following control
a.

Sequence Control

b. Individual Drive control

Analog Control
Alarms
e. Sequence of Event recording'

c.
d.

SYSTEM DESIGNPHILOSOPHY
FOR DDC SYSTEM

A4-10

415/ MPCL/ 001

REV. NO. 02

PAGE 10 OF 15

4.1.1 Sequence Control:

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In Step by Step mode the commands are released from the steps only after operator action
"ADVANCE" after release conditions are available. Other facilities like Monitoring time,
waiting tine etc are available in this mode also.

In Manual mode, output commands are blocked. The step proceeds with operator command
ADVANCE after release conditions are available.

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Sequence Control is designed using Sequence Master (SEQMSTR) and Sequence Step
(SEQSTP) Atomic blocks. One Sequence Master is used for both Startup and Shut down
programs. The sequence can operate in Automatic, Step by Step and Manual modes. These
modes are enabled depending on the requirement. The release conditions for progressing to
next step is programmed in each step. Unless the conditions are satisfied, the sequence does
not progress. Waiting time, monitoring time for each step can be programmed. Jump to any
step can also be programmed.
In Automatic mode the sequence progress without operator intervention if all the release
conditions for each step are available. The command from step is connected to the drive
level for automatic operation ofthe drives. In case the release conditions are not available in
the set time the sequence stops at that step with Monitoring time exceeded alarm. The
conditions available are displayed in green and those not available in red. The sequence
proceeds once the release conditions become available.

PAUSE button is provided to stop the sequence at any step.

The sequence is started by invoking the sequence popup. The Popup has buttons START and
STOP programs, ADVANCE and PAUSE buttons, and button for mode selection. With 'EX'
button operator can invoke a detailed sequence display which shows the current step,
Command issued by the step, release conditions (with their actual status) required for the
step, programmed monitoring and waiting time, program/step currently active, messages in
case of exceeding monitoring time, if the program is paused and in which step. On operating
button provided with each step , the release conditions and commands programmed
for each step can be Viewed.

'EX'

4.1.2 Drive Control:

Drive control programs are designed around DEVLOG atomic block. This block is suitable
for control of Unidirectionalibi-directional/Breaker/Solenoid drives. In all cases release
conditions and protection conditions are directly connected to the drive Control block
(DEVLOG).

SYSTEM DESIGN

415/ MPCL/ 001

PHILOSOPHY FOR DDC SYSTEM

PAGE

Il

OF 15

Operator can operate the drive by invoking the drive popup by clicking on the drive. Popups
have been customized for each type of drive taking into consideration the control

requirement.
The popups
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general will have buttons for ON/OF, OPEN/CLOSE and conesponding

indication. PERMIT buttons are provided to call permit popup which shows the release
conditions required to start or stop the drive. Fulfilled conditions are displayed in green and
unfulfilled in red. A FST button is provided for HT drives to display the trip condition. By
calling the FST popup operator can find out the first cause of trip with time stamping. The
trip signal ofall HT drives is tagged for SOE.

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4.1.2.1 t Bi-directional drives:

The DEVLOG atomic block is used along with other customized software to include torque
switch inputs and operation from backup control desk wherever provided. This customized
software will be used for motorized valves Dampers, inching valves. The drive command
cutoff either on Limit Switch or Torque switch actuation is programmable.

4,1.2.2 : Uni directional drives:

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Standard DEVLOG block with other blocks for pushbutton operation (wherever provided) is
used.

4.1,2.3 : Solenoid drives:

Standard DEVLOG block with other blocks for pushbutton operation (wherever provided) is
used.

4.1.2.4: Electrical Breakersl

Standard DEVLOG block with other blocks for pushbutton operation (wherever provided) is
Used.

4.1.3 : Analog Control

Analog controls are designed using standard Atomic blocks like::
4.1.3.1 Output Control

A control output value is provided by the combination of AUTOMAN and LIMITER atomic
blocks.

Svsren DEStcN PHILoSoPHY

41sMPCL/

001

FORDDC SYSTEM

PAGE 12 OF 15

with graphic input commands

AuToMAN atomic block provides the operator interface

In automatic operation' the
for target value, target it ",ti"'t' and mode selection' its control input' Automatic
from
AUTOMAN atomic block "ort;'orrtp"t is derived
quality acceptable and not
i, fr"rnally conditionaior, .oi. selection, input signal

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Value type forceback status.

Whennotautomatic,theAU-IOMANatomicblockcontroloutputisdirectedby.theoperator
the control output for
t'arget' Eorcetack can be configured to influence
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initializationorlimitapplicationo"tt"control-output'TheAUTOMANatomicblockOut

input value
,rrd O,r,fa, o,tr,put values (epresent the forceback
of the control output'
i.".,fr. fff,,ffiSR atomic block for indication of the result
rate of change and limit of operation and
The LIMITER uto.i" uto.t co,t,ol. th. o,tput
by application logic connections. It also
aoolies block and/or ovenidJ ""ii"", a"...ined
prouiaes status indications of control output limits'
4.1.3.2: Set Point Control:

combination of AUTOMAN and LIMITER

The control setpoint value is provided by the
Control function
atomic blocks in a similar manner to the Output

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is more important in this application to

Flexible forceback'application options selection
track the process value (the forceback
establish whether the local *alo'. *orting setpoint
outputvaluefromtherro;wr,iretneloop'ismanual.Modeselection(remote/local)forthe
when remote selected

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provides for the selection ofcascade control operation

4.1.3.3: PID Control

ThePlDatomicblockcalculatesthePlDcontrolactionfromitsprocessvariable.and
calculated from the basic

are
r.ip"i"ifrp*r. Proportional, i"itgt"f, *a Derivative-actions
Time (Minutes) tuning settings'
i-.if-ni"r"f Gain, Reset n.p*tJ pti Minute' and Ratecan
have separate weight from the

proportional and Derivative action from setpoint changes

the.setpoint multiplier factors. Filtering for
,r"l*r-rrr*ur. crrange actlon iy the settingis of
l"ir. i. ,rr. pro."r, ,iiubl" and/tr setpoint provided separately for each
control action:

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and setpoint'
Proportional action filter bands for process variable
Reset Filter Band And Gain Within The Band'

.RateGainadjustmentandanaltemativeratecalculationthatfacilitatestheapplicationof
a rate action filter band
forceback output to the setpoint when the
setpoint antiwindup function manipulates the
from the
pID forceback input indicates a t-oop itocti"g condition and the setpoint deviates
pr*".. iV *lrai"p tlrnit amount in the direction of the block'

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SYSTEM DESIGN
PHILOSOPHY FOR DDC SYSTEM

415/MPCL/ 001

PAGE 13 OF 15

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The FEEDFWD atomic block calculates Proportional and Derivative actions from the
feedforward process variable and combines the total action with the PID output. The control
action calculation is the same as the PID with the same adaptive tuning and filtering

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Feedforward is added to the basic control loop by inserting this atomic block following the
PID atomic block before the output conftol AutoManual atomic block. Multiple FEEDFWD
atomic blocks may be inserted, one for each feedforward function (or variable).

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Participation-Related Atomic Blocks

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These functions distribute controller output for control loops with multiple outputs

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PARTMEM
PARTMSTR

Participation by the PARTMSTR and PARTMEM atomic blocks coordinates the operation
of multiple confiol outputs from a single incremental control command. Distribution gain to
each control output is adjusted by the number and weight of the control outputs that will
respond to the distributed control command. The multiple confiol outputs are maintained in
a fixed relationship to each other by the participation equalizing control action. Changes in
member control outputs that will not respond to the distributed control command become
feedforward to the responding members. Members can be removed/added to participation
with their current position fed forward or not by logical command inputs
(Cancel or Cutout).
Correction Atomic blocks

Level and Flow correction are performed using the following atomic blocks.
LVLCOMP
FI,OWCOMP

SYSTEM DESIGN PHILOSOPHY

F'ORDDC SYSTEM

41s/MPCL/ 001
REV. NO. 02

PAGE 14 ()r'15

A4-10

Transmitter selection

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For Analog control, following popups are available:

transmitter selection
setpoint control
PID control
Master (wherever applicable)
analog drive control.

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Popup for
Popup for
Popup for
Popup for
Popup for

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4.1.3.4: Alarms:

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Transmitter selection for 2/3/4 selection is done by use of SIGSEL atomic block.

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system is a part of DDCMIS. Process alarms are generated in the respective

SG/TG/BOP FGUs. Hence the alarm annunciation is firnctionally distributed. The LVS
alarm annunciation utility is run in different OWS catering to different plant areas' viz., SG,
SG auxiliaries, TG, TG auxiliaries and electrical. When an alarm occurs, depending on the
plant area and severity, the same is displayed on the designated OWS. The window on the
left most side flashes with the severity color and indicate the tag description. Subsequent
alarms will add tbwards the right of the displayed window. It will initiate the audio (Hooter)

annunciation also.

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When any point returns to normal, if the point is in the visible zone, the corresponding
window will flash in green with the selected return to nomal sound.
Upon acknowledge and reset, letum to normal alarms will be cleared from the screen' In
case any point retums to normal which is in the non-visible zone, green button on the left
side will flash, indicating that some points in the non-visible zone are in retum to normal
state. Upon acknowledge and Reset the alarm points will be cleared.
any point which is in the visible zone goes to alarm state from return to normal (not
acknowledged/reset), then that particular window will flash again with the corresponding
severity color. Ifthe point is in non-visible zone, left button will flash with severity color.

If

SYSTEM DESIGN PHILOSOPHY

FORDDC SYSTEM

A4-10

41s/t\rPCL/ 001
REV. NO. 02

PAGE 15 OF 15

Anynewalarmcanbeacknowledged/resetwithasingleclickontherespectivealarm
window.

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OWS by pressing the

The audio annunciation can be silenced from any of the designated
SILENCE button on the vertical tool bar'

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4.1.3.5: Sequence of Events Recording:

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SequenceofEventsRecording(SoE)isintegratedinDDCMls.Thesignalsrequiredfor
SOE

ar.tugg"ainthedatabaseasperapproveddocument.Thesesignalsaletimestampedwith
1mS resolution.

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4.1.3.6: maxLINK:

indicated in the system

connectivity to third party systems ttuough this link will be as
configuration drawing.

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5.0 Reference Docriments:

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OGA for SG/TG,tsOP packages ;Dwg'no:36590000929
oPartitioningdiagram/ControllerGrouping.Doc.no:FG/415/.NIPCa.l002
HMI System Description'Doc'no:404/SD/212

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