Title of Document

FUNCTIONAL DESIGN SPECIFICATION

Project Name

2×60 MW WASHERY REJECT COAL BASED POWER PLANT

Project Location

USEAGAON,MAHARASHTRA
Project Number

3058621125
Document Number

3058621125-FDS
Equipment

OC4000

Customer : M/S GUPTA ENERGY PVT. LTD

Consultant: M/S HIQ POWER ASSOCIATES PVT. LTD

Supplier: M/S LARSEN & TOUBRO LTD

1
 INDEX

1. SYSTEM OVERVIEW

1.1 Introduction...……………………………………………………. 3
1.2 Architecture …………………………………………………….. 4
1.3 Salient features………………………………………………….. 5

2. SYSTEM HARDWARE
2.1 Distributed Process Unit (DPU) …………………………….. 7
2.2 Communication Cards………………………………………… 9
2.3 Input Output Cards…………………………………………….. 9
2.4 Real Time & Information Network…………………………...13
2.5 Engineering & Operating Station…………………………….17

3. SYSTEM SOFTWARE

3.1 Software Overview……………………………………………….19

3.2 Graphics Features..……………………………………………...21
3.3 Logic Builder……………………………………………………..37
3.4 Function Block Diagram…………………………………….....40
3.5 Plant data storage for analysis……………………………......41

4 ADDITIONAL FEATURES

4.1 Third Party Communication…………………………………….43

4.2 Firewall Interface………………………………………………….43
4.3 GPS Integration………………………………………………….. 43

2
 1.System Overview
1.1 Introduction

GE Distributed Control System (OC 4000) is designed to flexibly address a number of

applications ranging from plant-wide distributed control to stand-alone control and
protection of specific assets, such as turbines or boilers. Through the system’s
advanced fault-tolerant and redundant design features, reliable, robust control can be
configured to address even your most critical applications. The result is a control system
that easily adapts to your needs today, grows with you to meet tomorrow’s needs, and
delivers the reliability your applications demand.

The OC 4000 system colligates information, computer, network, database and

automation technologies with features of open system architecture, modular design,
powerful and intuitive engineering tools, comprehensive system self-diagnostic
capability, ease for operation and maintenance. It provides an integrated
management/supervisory and control platform for multifarious industrial process
automation applications, including power, metallurgical, petrochemical, paper and pulp,
cement, waste water processing and light railway transportation industries. The flexible
system configuration capability makes it suitable for small simple applications as well as
large complicated plant wide applications. The OC 4000 system consists of five types
of major components, HMI station, system network, controller, I/O modules and
powerful system software.

3
1.2 Architecture

OC4000 System Architecture

4
1.3 Salient features

OC 4000 System Characteristics

 Powerful Redundant DPU

System is backed up with redundant DPU. Changeover of DPU from primary to

Secondary is bump less and without effect on process.

Control of critical closed loop with high end perfection.

 Highly Reliable Communications

Redundant fault-tolerant and real-time backbone network using high-speed

Ethernet Open Connectivity
Open architecture with support for Modbus, Profibus, OPC, and other industry
standards

Globally distributed real-time database for secure, robust and high reliability.

Highly reliable real-time operating system

5
 Comprehensive self-diagnostic capabilities—from communication network down
to individual I/O channel.

 Flexible I/O

Intelligent I/O cards with low power consumption utilizing SMT technology

Support for local and remote I/O to reduce wiring costs

Redundant I/O network for high reliability

 User-Friendly HMI
Windows-based graphical process-oriented Human/Machine Interface (HMI)
Integrated translation-editing-free graphic configuration mode

Advanced “virtual DPU” technology supports off-line system configuration,

simulation, and debugging

 Easily Programmable Logical Blocks

System is incorporated with user easily understandable Function Blocks.

Special function Blocks are available for specific critical functions.

 Unique extra features

Self-diagnostics window is available to channel level monitoring.

Program/logic can be easily uploaded from DPU, which nullifies the requirement
of maintaining total backup of the DCS.
The DPU program/logic can be edited online. so no download is envisaged for
making any modifications.

The system’s Real-Time Fault-Tolerant Network (RTFNET) provides superior

reliability and availability between HMI and control layers through its double-ring
high-speed Ethernet backbone, allowing uninterrupted access to real-time
process information, alarms and events.

6
 2. System Hardware
2.1 Distributed Processing Unit (DPU)

As the main component of process control

the DPU undertakes data processing,
including analog signals, binary signals and
secondary processing, information
exchange, modulating control, logic control,
batch processing, advanced control strategy
and expert system function, etc.
OC 4000 DPU features high processing
speed, high reliability and strong capability.
It consists of the following components

Main Components

- Processor
In the core of the DPU is a 400MHz 32 bit microprocessor. It carries out the processing
and calculation of various real time tasks, i.e. control strategies, I/O signals processing
etc.
- High speed and reliable communication bus
Each DPU has two independent network communication interfaces that link with the real
time data highway, with a data transmitting speed of 100 Mbps. Through the interfaces
DPU broadcasts and receives data to and from the data highway.

- Colossal Data Memory

DPU is equipped with a maximum of 64MB RAM and a 64MB flash RAM. The RAM
stores process transient data supports processor’s maneuvering and calculation. The
flash RAM adopts advanced DOC Disk On Chip technology with no need of backup
battery, and is loaded with a real-time multi-task operation system, standard control
algorithms and control strategies. It provides a loss-power holding and automatic
restoration upon power on.

- Intuitive state indications

In the front plate of DPU there are LED indicators that display the DPU self-diagnostic
results. Customer can conveniently obtain from these indicators the DPU operation
status. Operators can acquire more detailed information of DPU diagnosis from the
operator station display screen.

7
- Special DPU switchover circuit
There is a special switchover card in each DPU. This card keeps watching and
diagnosing the counterpart DPU including each DPUs working mode. For hardware
logic is used for DPU data tracing and switching, it ensures the switchover between
master DPU and slave DPU to be fast and bump less.
As said above, DPU is the core of relatively independent process unit. Once DPU real-
time network loses communication, DPU responds quickly on the one hand, on the
other hand continues carrying out control task. In general, real-time network accident
won’t throw any influence on DPU running.
In summary, DPU provides a relatively independent processing function. When losing
communication with system data highway, a DPU can still perform specified tasks. In
other words, a failure of data highway will not impact DPU running itself.

Each DPU can supports I/O station: up to 12 I/O stations

Support remote I/O: distance up to 20 Km (fiber optic cable)

Electrical specification
Power feeds 220VAC or 24VDC
Power consumption 40W
Physical specification
Size 19" standard rack supporting two DPUs

Environmental specification
Operation temperature 50C to 500C
Storage temperature -200C ~ to 600C
Humidity 5% to 95% Non-condensing

8
2.2 Communication Card

Station control card for network - BCnet for short, is a card with time rectification
function, which undertakes management of cards in I/O station and fulfills
communication between I/O station and DPU via Ethernet. Being an updated version,
this BCnet card can receive timing signals from PCI timing Card and ensure SOE time
resolution of DI card, apart from its previous functions of I/O station communication and
management.

Main Characteristics
Ethernet interface band with 10M, twisted pair wire High precision real-time clock; 4
KHz SOE synchronous clock with resolution less than 1ms. Redundancy technique is
applied to build up a hot standby redundant structure of communication and control.

2.3 Input Output Cards

I/O card series of GE Energy's DCS are specially designed for the DCS system to
process real-time data acquisition from local device and to control these devices. These
cards are designed conforming to relative international standard. As each card has a
front panel on which reset button and indicator lights are mounted, and the card type is
displayed. In the rear part of the card there are two connector plugs. The upper one is
the communication bus, through which all data transmission and type identification of
cards are processed, while the lower one mainly serves for input and output signals
from local devices.
I/O cards are intelligent ones with high capability CPU. The different types of IO cards
are described as follows.

9
Analog input card mA
Analog input card (AI card) is mainly used for acquisition and processing of various
analog input signals. In DCS system, AI card is used as a front-end data server to
convert Analog input signals into corresponding digital signals, which are transmitted to
DPU via I/O bus.
The card is a low power consumption card and operates with mA_TB.

Temperature input card

Analog input card (AI TCRTD card) is mainly used for acquisition and processing of
various analog input signals. In DCS system, AI card is used as a front-end to convert
Analog input signals into corresponding digital signals, which are transmitted to DPU via
I/O bus. Thermocouple K, S, T, B, J, E etc and RTD Pt100, Pt10, Cu50, Cu100 are
supported.
The card is a low power consumption card and operates with TCRTD_TB.

Analog output card (AO)

The AO card provides 8 analog outputs to field devices. The control commands
generated in DPU are sent via BC-Net card to AO card, which then converts the digital
commands from DPU into relevant analog signals 4-20mA/0-20mA/0-10VDC to control
field devices.

Digital input card (DI/SOE)

The DI/SOE card is a multi-purpose, intelligent type binary signal card. This card
provides isolated, dual power supplies for interfacing to a group of 32 contact inputs.
Jumper selection is provided for selecting SOE mode. In OC 4000 system the DI/SOE
card receives, processes and converts field signals and then send via BC-Net card the
conditioned signals to DPU for further processing and application.

Digital output card (DO)

The DO card is an intelligent type binary signal output card. This card receives via BC-
Net card the commands generated in DPU and sends 16 relay outputs to field devices.
The contact capacity of the relays is 220 VAC/10A. When the field devices require DC
control, interposing DC relays are needed and supplied.

Summary of DCS cards

All I/O cards of GE Energy's DCS can be replaced online, that is, hot plug is supported.
But when replacing cards online, measures should be taken to ensure the normal
working of the controlled devices.

10
- High speed I/O bus

Each DPU can support up to 8 I/O stations and each I/O station can support up to 12
I/O cards. DPU and I/O station are linked by a high speed I/O bus with transmitting
speed of 10Mbps. The I/O station communicates in parallel way with I/O cards through
hardware circuit. The redundant I/O bus can support local I/O stations as well as remote
I/O stations (FIO). Each I/O station is equipped with two stations control cards that
control the station communication. The distance to a remote I/O that a I/O bus can
support depends on the bus medium. This distance can be as long as 20 Km when a
mono-mode fiber optic cable is used.

System Cabinet

OC 4000 cabinet is designed in conformity to international standards with

dimensions of 800mmX600mmX2200mm, front-rear door access. There are typically
two types of cabinets. One is control cabinet housing controllers (DPU), I/O cards, DC
power supply modules and AC power distribution box. Another cabinet is terminal
cabinet for mounting various types of terminal boards and connecting field signal
cables, which generally enter the cabinet from the bottom. Prefabricated cables are
used to connect I/O cards and terminal boards in the respective cabinets. The two
types of cabinets are generally arranged side-by-side, as shown below.

11
 799
525
735

65
2096
2175

2112
2210

25
53
25. 5

549
20 20
602

675
475

502

735

?16

712
792

Typical OC4000 System Cabinet

12
2.4 System Real Time & Information Network

Network architecture
OC 4000 system network consists of two portions, a 100Mbps redundant and fault
tolerant real time data highway, and a high-speed information network. This network
design splits real time data and management information so as to effectively reduce the
data flow load on the redundant data highway.

The redundant data highway (RTFNET) is a ring type, high speed (100 Mbps),
redundant fiber optic network (for small applications the data highway may be bus type
structure). It provides a link for all stations/nodes in the system. Each network in the
redundant configuration operates simultaneously, without master and slave, and
provides its counterpart a hot standby.

System Network Structure

The redundant data highway consists of industrial programmable switches , network

cables that link the system devices (nodes) together to constitute a complete distributed
system. Every device (node) in the system has direct access to the network through the
switches. In case a network breaks at one point between any two devices or a failed
device causes the failure of the ring topology, the ring network will automatically
degrade to a star topologic Ethernet and this will not impact the system operation.
This redundant and fault tolerant design significantly secures the reliability of the data
highway.

Information

13
Information network (INFNET)
The 1000Mbps information network is high-speed bus type network that connects all
HMI stations in the system. Non-real time information, i.e. historical data, logs, printout
data etc., is transmitted on the INFNET.

Network features

The system network is an information communication hub that provides a link for
transmitting various process data and information, such as control commands, real time
data, alarms, logs etc. A distributed control system like OC 4000 differs from a central
control system because it possesses a consummate communication system, a
distributed global data base, and each controller is of high level self-governing function
and is transparent to other nodes in the system. OC 4000 adopts the high efficient, high
speed, redundant and fault tolerant ring type network and a high-speed information
network, through which the HMI stations and DPUs directly connect together. This
design provides following features.
Redundant and fault tolerant network ---- A field proven, reliable industrial network
structure
- Fault tolerance- The real time data highway of OC 4000 uses dual ring structure. All
stations/nodes in the system directly access the network. The rings possess self-
curing function, which enables to generate a new communication loop in case a
break at any place of the ring. A single break in the ring will not impact its
operation. See fig. 2-2.
- Redundancy- OC 4000 provides redundant data highway. Two ring type data
highways are redundant with each other, without master or slave, and operate
simultaneously, with no need of switchover and arbitration between the two rings.
This redundant and fault tolerant design tremendously increases the network reliability.
It is an advanced network technology.

Concept of a Typical OC 4000 Single Ring Fault Tolerance

14
High speed and high efficiency ---- A guaranty of system fast response
High speed OC 4000 data highway provides a complete dual operation, broadcasting
communication with a bandwidth of 200 Mbps (dual duplex method).

High efficiency OC 4000 provides separate real time network and information network,
which splits the real time data, such as real time data, commands and alarms, and non
real time data, such as historical data, tables and logs, alarm history retrieval. This
design efficiently reduces the real-time network load rate.

High speed information network ------ facilitating on line test and maintenance
The unique information network design provides not only a non-real time data
transmission channel, but also a channel to manage system on line resources. All data
and information in connection with logs, resource, peripherals (printers and CD-RWs)
can be shared by HMI stations. Any data and graphic displays can be tested and
modified on line via the information network, which will not impact any running tasks.

The RTFNET of OC 4000 complies with the international high speed Ethernet field bus
standard HSE. It employs the exchange type Ethernet, one of the high speed Ethernet
structures. The remarkable advantage of this type of Ethernet rests with its complete
dual operation mode, which provides a high communication speed, 100Mbps, for each
system node. This ensures a very low network load rate of whole DCS. The following
is a calculation of OC 4000 network load rate.

Specifications of OC 4000 networks

RTFNET—Real Time Network

Medium access standard IEEE 802.3u

Communication method Broadcast or point to point （Dual Duplex）

Communication protocol TCP/IP

Data transmitting speed 100 Mbps

Network structure Dual ring fast Ethernet

Medium 100 BASE-TX：

Two pair twisted cable, type 5, non-shielded（100
M）
100BASE-FX：
62.5/125µm multimode fiber optic cable（2 Km ）

15
 RTFNET—Real Time Network

Node capacity 250 nodes

Signal capacity 64000 signals per second

INFNET— Information Network

Medium access standard IEEE 802.3u

Communication protocol TCP/IP

Data transmitting speed 100Mbps

Topological structure High speed Ethernet

Medium 1000 BASE-TX：

Two pair twisted cable, type 5, non-shielded（100
M）
Fiber optic cable available
Node capacity 40 nodes

Communication method Point to point

16
2.5 Engineering & Operator Stations

In typical system configuration, computers as per minimum specification furnished are

used as HMI stations, i.e. operator stations, engineer station, historian/log station and
multifunctional interface station. All HMI stations are comprised of identical hardware
and system software. The stations provide different functions in accordance with user
definition and authorization.
DCS HMI stations consist of commercially available computers, functional
application software based upon Windows software platform. All DCS HMI stations can
be of same hardware and software in configuration, multi operation modes, i. e. engineer
station mode, operator station mode, historical data station mode/performance calculation
station mode. The software password design prevents the dedicated station from
unauthorized intrusions.

Engineering Station (ENG)

The DCS engineer station provides powerful configuration tools that allow the user to
create, download, and edit process graphics, control strategies and logic, and process
point databases. The ENG can operate at OPU mode.

DPS-400 developer studio integrates a group of advanced software programs for

creating and maintaining control strategies, process graphics, point records, I/O
placement, report generators, and system-wide configurations.

Features:
 Simultaneous engineering of control, database and graphics through multiple
windows.
 Intuitive Developer Studio generates object-oriented graphics, system database
and control.
 Easy configuration of the DCS system through standard tools such as cut, paste,
and drag-and-drop.
 Dual functionality as an Operator Workstation minimizes hardware costs.
 Changes can be done online where results can be seen with immediate effect.
Removing any block from scanning and/or forcing its O/P is just a matter of one
right-click and then selecting the right option.
 Straightforward installation through standard Microsoft Windows procedures.

Operator Station (OPU)

DCS operator software provides a dynamic view of all plant processes with the stability,
performance, and flexibility needed to operate modern control systems.

The DCS operator unit (OPU) provides a high-resolution window to the process for
control graphics, diagnostics, trending, alarms and plant status displays. Through the
OPU, the operator has access to dynamic system signals as well as historical data,

17
standard function displays, event logs, and a sophisticated alarm management program
through intuitive navigation tools, icons or standard Windows desktop menus.
Operator software can be implemented on various PC platforms, providing flexibility in
processing performance to match budgetary needs. Compatibility with many third-party
applications and components makes the OPU ready for upgrade to meet future plant
requirements.

Features:
 Standard operating desktop environment
 Full multi-tasking operation
 Accesses up to 64,000 dynamic points
 Intuitive graphics configuration
 Easy navigation through alarms and displays
 Pre-defined templates available for faceplates, graphics, and trends
 Sophisticated alarm management
 Real-time and historic trending
 Interfaces with a variety of third-party applications and components
 Supports multiple languages, character sets, and cultural conventions

18
 3. System Software
3.1 Software Overview

NetWin is the software for the database management and network communication
management of DCS. Before starting any other software, you must first launch the
general control program, i.e., to start the DCS real-time database management and
real-time network management drivers. Meanwhile, NetWin is used to display the status
of the realtime network, set the path of project data, store configuration data of the
project, and display MMI node number and operation levels. The MMI node with the
highest level has the right to administer the network, and it can check the timer of the
node on the network.

Control Software: NETWIN

Graphics
Network Maker
Status
Logic
Software
System
Configuration
Netwotk
Status

Time Setting Node

Details

Main
Node

19
 Programs can be run through Netwin interface. In both toolbar and "Application
(P)" menu we can find the following programs:

DPU configuration :A user-friendly, intuitive, graphics - based software package

for the creation of DCS control strategies and automatically generates executable
code for downloading to the DPUs.

Graphic making : Enables fast creation and editing of high-resolution process

graphics using normal click and drag drawing features, providing color, line, fill,
and shape menus and custom symbol and object libraries.

Self test : Self-test is a monitoring program of software which is used to monitor

the status of the nodes in the redundant realtime network, the I/O station in the
DPU in the system, and each channel of the I/O cards in the I/O station.

Data list : Xlist is used to monitor the real-time data in the global point database
on MMI.
Trend : This software displays in graphic form the real-time trend and historical
trend of the points. It offers tool bar, trend pane,trend point value etc.

Single point : Single displays the real-time data of the point on a process
variable within the global database, and it is easy to online modify the status,
alarm and real-time value of the point. This software is used together with other
software for the debugging and controlling of the whole system.

Alarm history : This software is used to display the record of the queue and the
alarm history file, with different fonts and colors to differentiate the record types

Alarm list : This software is used to monitor the real-time alarms in the global
point database, with different colors to visually display the priorities of the alarm
points

Graphic vew: Graphic display software is the most commonly used software of
OPU, being man-machine interface. The operation station provides the operating
environment for the screen-oriented operation, monitoring and control, enabling
the operators to monitor the production process through various display screens
such as flow chart, alarm, and trend, etc.

TabPrn: This software works as the human-machine interface to select the

report format and printing time

20
3.2 Graphics Features

OC4000 is enriched with simple user-friendly in-built graphics software with core
software. Plant description can cauterize in the form of pictures using the high-end
drawing tools of graphics software.

Real-Time Graphic: SHOW

Window 1

Window 2

Window 3

Window 4

Control
Panel

The SHOW application is the Real-time graphics page. The operator monitors
and issues command from these graphical pages. The drive control is done from the
pop up faceplate from the graphics. It supports up to multiple Graphical window.

21
 Control Panel

Link Alarm Display Alarm Point Display Process System Alarm

Parameter

Control Panel helps the operator to monitor the important parameters and the alarm
summary while operating the plant through graphical screens. Also it has Links for easy
navigation.

1. Link: Link to the various INDEX pages of individual Functional group. This helps
the Operator in faster navigation.
2. Alarm Display: It Displays the summary of top 4 priority alarms of each group.
3. Alarm point Display: This section gives the point details of the higher priority
alarms. These alarms points are configurable as per the operator requirement.
4. Process Parameter: The important process parameters are displayed.
5. System Alarm: The link to system alarm. This gives the list of control system
related alarms.

22
Graphic Builder- MAKER

The Real-time graphics are created with the Maker application of OC4000 System.

Basic figure object drawing

Advanced figure object inserting.
Large built-in grouped object library
Easy to add user-defined object
Easy to make dynamic link
Multi-Layer support

Graphic Attribute:

Graphic attributes are the properties related to a object and its dynamics such as base
color of the object,change of color as per some predefined conditions etc.Following
graphic attributes will be used as a standard unless otherwise specified:

Color of the static object -Standard Grey.

Background color of gradhic window -Light Grey.
Window size -1280 X 920.
Window name will be written using font Arial-18,White,Bold.
Line Thickness- 0T/1T/2T/3T/4T as per the aspect ratio.
White,Dotted, 0T line for instrument signals.
Name of object will be writtwn using Arial-12,Black,Bold.
PV/SP/OP value will be displayed using Arial-12,Bold with their respective colors.
Vertical Line will give way to horizontal line.
Thinner line will give way to thicker line.
There will not be intersection of the lines like this-
Distance between parallel lines- Minimum 1T of thicker line.
Line will not bend at any angle other than 90 degree.
Direction of Process Fluid will be shown using arrow marks near to the point of
entry/exit.
Customer has to submit the schedule of line thickness as well as color for
diffeternt Process Fluids.

23
Graphics Maker Page

24
List of Colour available :

25
Line Type and thickness available:

26
Faceplate

DIGITAL DRIVE
(OLCS) FACEPLATE

ANALOG
CONTROL(CLCS)
FACEPLATE

DRIVE SELECT
FACEPLATE

27
 OLCS Operations Face Plate

Type-1 Motor/Pump/Fan

1.Tag and Description

6. Drive Fault Indications 2. Operator Lock

3. Fault Ack/Reset
7. Drive Commands

4. Drive Feedbacks

5. Protections/Permissives
Indications

1. Tag & Description: The Tag number and the Tag description will be displayed in
this area.
2. Operator Lock: The drive operation from the DCS HMI can be disabled by
operation of this button. This operation is enabled only for operators of Super
Operator level.
3. Fault Ack/Reset: The drive related fault could be acknowledged.
4. Drive Feedback: The Start and Stop drive feedback is displayed.
5. Protection/Permissive Indication: The start stop permissive and protection
indications are available in this area. D1P and D2P correspond to start and stop
permissive respectively. EMD1 and EMD2 correspond to start and stop
protection respectively.
6. Drive fault Indication: The entire Drive faults are indicated on the top of the
control buttons.
7. Drive Command Buttons: The drive can be started and stopped using these
buttons. These are enabled if the corresponding command permissive is present
and the protection is not present.

28
 Type-2 Motorized Valve / Dampers

1.Tag and Description

6. Valve Fault Indications

2. Operator Lock

3. Fault Ack/Reset
7. Valve Commands
4. Valve Feedbacks

5. Protections/Permissives
Indications

1. Tag & Description: The Tag number and the Tag description will be displayed
in this area.
2. Operator Lock: The drive operation from the DCS HMI can be disabled by
operation of this button. This operation is enabled only for operators of Super
Operator level.
3. Fault Ack/Reset: The drive related fault could be acknowledged.
4. Drive Feedback: The Start and Stop drive feedback is displayed.
5. Protection/Permissive Indication: The start stop permissive and protection
indications are available in this area. D1P and D2P correspond to start and
stop permissive respectively. EMD1 and EMD2 correspond to start and stop
protection respectively.
6. Drive fault Indication: The entire Drive faults are indicated on the top of the
control buttons.
7. Drive Command Buttons: The drive can be started and stopped using these
buttons. These are enabled if the corresponding command permissive is
present and the protection is not present.

29
System Diagnostics: SELFTEST

Selftest displays the overall system diagnostics.

Selftest enables the operator to monitor:

Overall status of the stations on OC4000 Network.

Diagnostic and mode of DPU, VDPU, Operator station unit, Historian Station Unit
and Engineering Station unit.

SYSTEM

DPU/CONTROLLER

I/O CARD

IO CHANNEL

Diagnostic of IO stations.
Diagnostic of all IO cards.
Diagnostic of individual channel of all IO Cards.
Diagnostic of channels on the Virtual I/O cards.

30
 Alarm Annunciation: Alarm List & Alarm Historian

Alarm List

Analog/Digital Filtering Point Detail Page/Point Ack

Timer

Filtering

Acknowledge
Alarm Point

Active Alarm
Point

The Alarm page displays alarms from the Process, System, and operator actions and
configurations changes.

31
Alarms can be filtered as:
1.Analog / Digital Signal
2.Acknowledged / Non Acknowledge signals
Also as per
1.Node 2.Description 3.Attribute Code.

The filtering can also be done using wildcards of "*" and "?".
A single alarm can be acknowledged or the page acknowledgment button can be
used to acknowledge the Active alarm page.
All the alarms are listed in millisecond resolution.
The display of alarms is in various defined foreground and Background color for
different priorities and acknowledgment status. Colors are assigned for alarms of
different priority
The point details of the alarm point can viewed from alarm page
Timer function is used for disabling the real-time refresh process.

32
 Alarm Historian

Analog/Digital Filtering

Time Frame
selection

OP Cmd Notices
/Acks
SOE
Timer Filtering
Debug
s

All the commands issued by operator are shown and the operator log is also created.
Notices and Debug messages are also available in the Alarm Histo

Alarm Point Print

Alarm Historian page displays alarms from the Process, System, and operator
actions and configurations changes also the signals, which has been removed
from the alarm list.
Operator can view the alarms within a selectable time frame.

Alarms can be filtered as:

1.Analog / Digital Signal
2.Acknowledged / Non Acknowledge signals
3.Operator Commands
4.Operator Acknowledge
5.Notices
6.Debugs

33
 Sequence Of Events (SOE) list can be viewed separately.
Alarm point print preview and print functions are available at press of a button.
All the alarms are listed in millisecond resolution.
Display of alarms is in various defined foreground and Background color for
different priorities and acknowledgment status. Colors are assigned for alarms of
different priority
Point details of the alarm point can viewed from alarm page
Timer function is used for disabling the real-time refresh process.

Annunciation Panel

Annunciation Window with important alarm points of each functional group/Plant

area can be configured. Thus the operator can easily monitor the alarms and the
equipment conditions.
Alarms can be acknowledged from the same page.

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 Real Time Data Base Management

Point Type Analog, Point Display Print Dynamic Characteristics

Digital, Node. Filtering

Source node Name Description

The Database of the system can be managed using the Xlist function.
Troubleshooting features are also included in the application
All the points including the hardware, soft points, system diagnostic points are all
included in the Xlist. This enables us in using Xlist for detecting system faults.
Monitoring the properties of global real-time data
Divided into Analog display and Digital display
Filtered by static characteristic

1.Point-type, 2.Node-number, 3.Point-name, 4. Point-description.

Filtered by dynamic characteristic

1.Quality, 2.scanning cut point, 3.alarm point, and 4.unspecified alarm point

Call Single Point Display Software

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 Real Time & Historic Trend

Real Time Process

Point Tag Description Value Engg Unit

Real-time data trend display: Online values of the process parameters can be
viewed.
Historical data trend display: The historical values of the process points from the
historian can be viewed.
Trend group and points configuration: Up to 8 Parameters can be configured in a
trend group. The trend groups also can be distributed to 4 windows.
Trend data conversion to text files: The parameter values of the trend with
respect to the scale time can be converted into a test file for further analysis.
Display data in graphic mode or list mode: The trend can be selected in two-view
modes .In the graphic mode and list mode. In list mode we can monitor the array
of process values against the time.

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3.3 Logic Builder

OC 4000 system provides a complete set of process control software package

with powerful functions including signal processing, continuous control, logical
arithmetic, sequence control and control arithmetic for various advanced control
strategies, which can be configured to various control solutions for different applications,
simple and complicated, small and large. The process control software of OC 4000
system conforms to programmable control language standard IEC1131-3. An algorithm
library in engineer software package provides more than 100 built in algorithm blocks for
system configuration and debugging. Programming with this engineering tool is as easy
as just dragging algorithm blocks from the library and connecting with lines. Program
compiling is done by the intelligent software automatically.

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 Engineering Software- DPUCFG

2.Edit 3.Upload, 4.Page 5.View 6.Block

1.DPU File
Function Download Edit Control Control
Management

7.Allignment
9.List
Window

8.Edit Window

The DCS engineer station provides powerful configuration tool that allow the user
to create, download, and edit control strategies and logic, and process point databases.
The Engineering Station (ENG) can operate in OPU mode.
The main function of DPUCFg are
DPU off-line configuration
DPU can be configured off line and saved on Engineering station disk. The
configuration interface meets the IEC-1131-3 standard concerning graphic configuration
function blocks.
DPU configuration download, online configuration and debugging
The configuration files on Engineering station hard disk can be downloaded into
DPU. And the user also can directly modify, operate, debug the DPU as well as observe
the trend curve on graphic configuration interface.
DPU configuration files saving
Configuration in DPU can be uploaded into Engineering station and saved to
Engineering station disk.

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Tools

1. DPU Off-line File Management:The following off-line file functions can be done.
Create new off-line DPU configuration file
Open existing off-line DPU configuration file
Save current off-line DPU configuration file
2. Edit Function: Edit functions like Delete, Copy & Paste, Delete, Cancel operation
and return to previous state can be done.
3. DPU online Control: Used to control DPU online like
Link online DPU
Upload configuration in DPU to Engineering Station
Download off-line configuration file on Engineering Station to DPU
Read off-line configuration file on Engineering Station in to DPU for
downloading
Save DPU configuration files to configuration files on Engineering Station
Disconnect the link with DPU
DPU master/slave controlling and upgrading
4. Page Edit:Used to append or delete DPU configuration page.
Append new configuration page
Delete configuration page
5. View Control:Used to perform View control over DPU configuration page.
Select blocks in configuration page
Zoom in part of the image in configuration page
Move configuration page in edit window
Go back to the previous edit window
6. Block Control: Used to call function block library and to search and edit block.
Call algorithm function library
Search the whole configuration for the setting function block
Find/Replace text, pin description and point name
Display point directory data of this node.
7. Alignment:Used to align the selected blocks (two or more) in a certain way
Left Sides, align selected blocks to the left.
Right Sides, align selected blocks to the right .
Tops, align selected blocks to the top.
Bottoms, align selected blocks to the bottom.
8. List window: List window for listing files, DPU and pages.
9. Edit window: Edit window for editing attribute of pages or DPU. Users can
configure DPU algorithm in this window.

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3.4 Function Block Diagram

Typical Power Plant Specific Software Block

The power plant specific blocks are incorporated to aid

faster,and easy engineering. Also the blocks like PTCal
gives a option for optimization and caters to the power plant

PTCal Block
PTCal block Calculate thermal parameters like enthalpy specific
volume etc. of Steam/Water.Calculation Mode can be selected
This block is used for optimization and performance
calculation. Also aids in specialized control loops.
In supercritical boilers the feedwater loop is controlled and
optimized using the PTCal block enthalpy mode.

ThrSel Block
One out of three selector block.
ThrSel block accepts 3 analog inputs with 07 selectable outputs.
Select the output according to: Mode, Deviation, and Input quality.
Three or two transmitter selection can be done with this block

First Block
First block identifies the first up condition. 16 conditions can be
connected to the block and the first up signal can be identified.
It comes with manual reset function. The block can be cascade
To get first up for multiple of 16 inputs as well.Generally it’s used
to indicate MFT,Turbine and other major drive’s first cause

Device Block
Device block is a universal block that can be used for any drive with just
the mode selection. This gives uniformity and ease during engineering and
fastens trouble shooting during maintenance phase.
The drive alarms are incorporated into the block and doesn’t need extra
programming.
Device block is used for HT drive, LT drives both unidirectional and bidirectional,
inching type valve, solenoid valve etc.

LvlComp Block
LvlComp achieves drum level compensation.
The actual drum level is calculated from measured level
with pressure and temperature.All steam drum level
measurement and control the LvlComp is used.

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3.5 Plant data storage for analysis

LongTime Data Storage-HISTORIAN

The Historian Station unit of the OC4000 System does the archiving and recording of all
the database points.

Features of the HSU are:

Support more than 100,000 points per server

Scan time less than 100 ms
Dead band compression
Swinging door compression
Interface and storage buffer mechanism
Data storage structure optimization in archives
OLEDB Driver

Reports & Logs- DATA LOGGING PACKAGE

Logs and reports in OC4000 system can be broadly divided into the following types.

Periodic Report: To record and output the numeric value of the analog value or the
status of the digital value in the specified time period. They are usually used to generate
the shift reports, daily reports, monthly reports, and others.

1.Daily report, 2.Hourly report, 3.Shift Report

Event Report: to record the change of the digital value or the out-limit of the analog
value, such as the event in which a digital value changes from "1" to "0" or an analog
value goes out of the set limit. When such an event happens, its start time, end time,
duration, the maximum (minimum) value, the time when the maximum (minimum) value
occurs, and other information are recorded.
1.SOE Report, 2.Alarm Log, 3.Operator Action log

Triggered Report: to view the statistics when a digital value changes. For example, the
statistics starts when the digital value changes from "1" to "0" and ends when it changes
from "0" back to "1". In other words, it is the statistics while the status of the digital value
is "0". Therefore, the triggering condition of a triggered report must be a status of "1" or
"0" for a digital point. In the duration of this status, you can gather the statistics of the

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digital values and analog values related to the digital value, such as the average value,
the maximum value, the times of the replacement, and other data.

1.Post Trip Report, 2.Trip Log, 3.Maintenance Log

The formats and templates of logs and reports are user configurable. The
templates are based on Microsoft excel, which makes it more user
friendly and adaptable.

The logs and reports can be printed at a scheduled time or as the report is
generated.

All the reports are stored in the operator stations for future reference and
are archived at regular intervals.

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 5.Additional Features
5.1 Third Party Communication

OC 4000 can talk to any third party software or Controller through gateway. It supports
bi-directional communication with third party devices.

5.2 Firewall Interface

OC 4000 can communicate with Level-II automation with software as well as hardware
firewall protection. Information network is taking care of this integration. Hardware
firewall is put in between the Information network switch and Level-II integrity switch.
Plant network is getting highly protected through firewall.

5.3 GPS Integration

OC4000 system can be synchronized with GPS. It supports all kind of standard outputs
(IRIG-B, NTP, SNTP etc) from any standard GPS manufacturer.

Connection of Time-synchronization Network

The connection method of time-synchronization network, exemplified by star topology

net via twisted pair, is shown as in diagram below.
Time-synchronization network exemplified by star topology net via twisted pair 9

As part of MMI station, two PCI clock cards are allocated respectively to both master
and slave OPU stations. The cards receive PPS signals and timing information from
GPS, and transmit second pulse and timing information to different Bcnet cards of DCS
through two RS485 channels to ensure synchronization of the system.

I/O bus board has the time-synchronization function equipped with the following cable:

PCI time card time-synchronization cable

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The connection method is as follows:

GPS clock card connects with PCI time card through time-distribution cable of PCI
clock. PCI time card connects with Bcnet through time-distribution cable of PCI clock.
On I/O bus board, two D-type 9-pin sockets, U15, U16, are used to connecting time-
synchronization cable. In most cases, one socket connects inlet cable, while the other
connects outlet cable, so that the I/O station s of time-synchronization are connected in
series. Bcnet and I/O HUB are connected through Ethernet cable. On I/O bus board,
two D-type 9-pin sockets, U13 U14 are used to connecting time-synchronization cable.

Time Synchronizing Network

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