plantpax: a "whole plant" control solution for power generation

Copyright © 2014 Rockwell Automation, Inc. All Rights Reserved.

PUBLIC INFORMATION

A "Whole Plant" Control Solution for Power GenerationLee J Ward, Regional Business Manager, Heavy Industries


Look into the heart of Combined Cycle PGP


The Control Room

AlarmingPower Quality

Balance of Plant Pollution Control

Safety Systems

Turbine Control

Fuel Management

Steam Generation

Waste Management


Traditional DCS are good, but……

Usually you are tied to the vendor for the life of the plant Support and maintenance become an exclusive contract Specialist resources are at a premium Creates a “two tier” expertise level for plant control Knowledge base is therefore limited Plant upgrades and equipment obsolescence are a challenge Difficult to incorporate new standards and field devices Life cycle costs are high


Non Traditional Approach

Unlike a traditional DCS, a process controller offers unparalleled flexibility – You can do what you want

BOP Integration becomes less of an issue Foreign device interfaces are easily supported Advanced features are a choice One skillset Unlimited knowledge/resource Continuous migration paths Obsolescence protected Lower TCO

Copyri5


Definition

6

A distributed control system (DCS) refers to a control systemusually of a manufacturing system, process or any kind of dynamic system, in which the controller elements are not central in location (like the brain) but are distributed throughout the system with each component sub-system controlled by one or more controllers


Recognize this?

7


Key Power Plant Elements

8

ExcitationSynchExcitationSynch

ExcitationSynchExcitationSynch


Does this fit the definition?

OWSFactoryTalkHistorian ServerEWS

ViewServer

FuelManagement

TurbineControl

HRSGBurner MgtHRSGComb CtrlHRSGSCR

GeneratorControl

GeneratorControlSteamTurbine

FeedWater

Condensate

ProtectiveRelay

CoolingSystem

DrumLevel

BOP

PlantMaster

Fiber Ring

SoftwareCEM


Plant Control Focus Points

High Availability – Uptime is Prime Scalable Architecture – One size does not fit all. One platform can! Robust Communication – Open, but secure. Grand Master of Time – One version of the truth Sequence of Events – When did it happen? Alarming – Event and Priority Management Historical Data – What happened? Condition Monitoring – Stop it before it happens Easy Integration – Native and Foreign Device Interface Integrated BOP – Drives and MCC’s Instrumentation Asset Management Advanced Process Control - Optimization


Scalable Core

Visualization

CentralizedEngineering

ProcessControl

CommunicationInfrastructure

System Tools & Utilities

SystemEstimatorProcess

Library

System Extensions

Batch Management& Control

ProcessInformation

Critical Control& Safety

Power & Field Devices

InteroperableField Instrumentation

Motor ControlCenters

ConditionMonitoringSystem

Drives

APCAsset Management

Implementation Tools

Typical Core and System Capabilities


Process Automation Controller

Global access to data Deterministic control Extensive process library Redundancy

High speed logic Standalone operation Saleable architecture Interfaces to many devices

Beyond hybrid system - single platform for all control disciplines Common programming tool Source stored in controller, tag based Integrated network infrastructure High functionality I/O: RIUP, diagnostics, isolation Wide range of I/O platforms: rack-based, distributed

DCS ControllersDCS Controllers Traditional PLCTraditional PLCProcess Automation ControllerProcess Automation Controller

Adds

Adds

ARC: Programmable Automation Controllers (PACs) are multi-disciplined controllers capable of providing real-time logic, motion and process control, in addition to HMI and other functions, on a single platform

Copyright © 2014 Rockwell Automation, Inc. All Rights Reserved. 13

Centralized Engineering Simplified Configuration Effort Single starting point

Synchronization w/ running system

Modularity & Reuse Library for managing reusable

logic

Copy/paste; Drag/drop; XML-based Import/export

Complete Toolset System View, Logic Editor, HMI

Designer, Batch Configuration, Process Networks, etc…


Develop & Maintain Application Code

Create & Manage System Displays

Store & Access Documentation

Launch Support Applications

System Development Environment


System Development Environment

Library for AOIs and UDTs

Controller View

Assign I/O AliasesManage Produced & Consumed Tags

System-Wide Search


Informative Visualization

16


CNB

DIN

AIN

SOE

SOE

EN2T

ControlNet

Primary Chassis Secondary

Chassis

F.0. Cable (Cross Loading)

HI PROM GPS Module is the Real Time Source and Grand Master (GM) of time to Synch Redundant Controller Wall Clocks and SOE (Event) Time Stamping.

RM

L6X

CN2

EN2T

CNB

DIN

SOE

SOE

EN2T

GPS

A & E Controller

L7X

Stratix 8k (1588ptp)

NTP Clients

PTPPTP/NTP

Grand Master of Time – Satellite Synched

• Resilient / redundant• 1756-Time GPS module:Grand Master of time, not just a time source• CIP Synch using EtherNet/IP

S

RM

L6X

CN2

EN2T

GM GM

SS


Easy Configuration

18


High speed event capture – 10 - 20 μS 64bit Time stamp When did the event occur? What happened first? What action to take? Linked to Alarms & Events Linked to FactoryTalk Historian

Sequence of Events (SOE)


Modern Process Control Library Suite of ready to use Device Level Control

Modules

Content:

Control instructions

Graphic objects

Operations and Configuration Faceplates

Fully documented - PDF manuals for all Instructions

Premier Integration

Control code linked to devices

Automated tag data generation

Seamless communication


Graphic Objects

Motor FBD

Interlock FBD

Operator Faceplates

Interlock Object

Application Code

Motor Objects

Modern Process Control Library


System Alarm Management

The Alarm Summary provides extensive information to assist the operator in determining an appropriate response to an alarm

Configurable views of the system alarms allow the operator to customize the display enabling the operator to focus on events from a specific area of control or interest


System Alarm Management

Alarms are individually color-coded for easy determination of active alarms and their priority

Links between alarms and associated controls or displays provide direct access for rapid resolution of abnormal situations


Scalable Historian Solution

SUPERVISOR

MANAGEMENT

OPERATOR

FactoryTalk Historian Enterprise Edition

FactoryTalk Historian Site Edition

Historian Machine EditionRight Information, Right Time, Right Fidelity and Applications


Historical DataThe Operator Workstation and Application Server-FactoryTalk Historian provide the ability to visualize specific process operations over a period of time

The Local Datalog provides operators with configurable short term / “real time” data capture and trend displays for quick analysis of the process’s operation

The FactoryTalk Historian collects data across the plant over periods of time for long term system analysis and optimization

Collect information from native Integrated Architecture® control and production management components

Collect data from third-party systems which are interfaced or otherwise integrated with the Integrated Architecture for process system


Why the Power Industry Needs Integrated Condition Monitoring


Library Faceplates for the Operator -Maintenance - Engineering


Native and Foreign Device Interface

EtherNet/IP

ControlNet

DeviceNet

Profibus DP, PA

HART

Foundation Fieldbus

DH+

DH485

DH1

GE Genius

TI 500/505

DNP3

IEC61850

Modbus

Modbus TCP

Modbus Plus

S908 RIO

LonWorks

BACNet

FipIO

CANOpen

ASI


Integrated Balance of Plant (BOP)

Electronic Overload Relays

Variable Frequency AC Drives

Soft Starters

Power Monitoring Equipment

Programmable ControllersDeviceNet I/O

Third Party OEM’s


Whole Plant - InstrumentationAsset Mgmt Software

ControlLogix®

FF H1

OWS EWS

3rd Party interfaces to:Building Automation Systems,

Chillers & Boilers


Instrumentation Integration

Add-On Instructions (AOI) and Faceplates

Pre-designed AOIs provide a two-way exchange of data between the faceplates and the process automation controller

FactoryTalk View SE faceplates provide visualization of instruments connected to a 1756-IF8H HART module

Copyright © 2014 Rockwell Automation, Inc. All Rights Reserved. 33

Faceplates provide directly from the instrument: Tag name, Description,

Message/Label, Engineering Units, Zero and Span, Analog fault status

HART PV (first, second, third), HART PV fault status

Diagnostic Information Device specific error codes,

warnings, information, etc. Configure the faceplates to provide: Mode (such as operator or program),

High-high, high, low, and low-low alarms, Over-range and under-range alarms, Alarm delay, Alarm hysteresis

Instrumentation Integration


Real-time Optimization

Model PredictiveControl

Nonlinear multivariable control

Linear multivariable control

Inferential Sensors

Advanced Regulatory Control

Regulatory Control

Advanced Process Control Scalable to meet a wide range of advanced process control requirements Improve yield, increase throughput, reduce costs and improve quality

• Economic optimization

• Maximize throughput• Increase yield• Reduce variability• Improve product transition

• Virtual lab readings

• Basic loop PID controlIncr

easi

ng E

ffort

& In

crea

sing

Val

ue

Pavilion8Dynamic MPC

PlantPAx Fuzzy Designer

Logix IMC, CC, MMC

Logix PID, PIDE, AOI

PlantPAx® Model Builder


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What is Model Predictive Control (MPC)?

Classical MPC algorithms: Dynamic identification Multivariate Parametric dynamic modelsLinear and nonlinear gain/dynamics: Models handling industries Broadest application space

Fully functional economic nonlinear optimization available in same application or product

Interacts directly with over ten different DCS/SCADA systems Interface is Pavilion GUI or Standard operator DCS interface Dynamic cascade visibility, trajectories


What does MPC do?

Minimize operational variance

DV CV

Transition effectively

CV

Follow operational plan

CV

SPECIFICATION OR LIMIT

BEFORE MODEL PREDICTIVE CONTROL

WITH MODEL PREDICTIVE CONTROLAND OPTIMIZATION

TIME

KEY

TA

RG

ET

Copyright © 2014 Rockwell Automation, Inc. All Rights Reserved.(Confidential – For Internal Use Only) 38

The Software Continuous Emissions Monitoring (CEM) Solution

Consists of an emission model that reflects the relationship between process operations and ambient conditions to emissions

Copyright © 2009 Rockwell Software. All rights reserved.

A patented, sensor validation system to ensure the accuracy of the predicted emissions data.


Integrating the Switch Yard with IEC 61850

Network setup

Substation automation

Load shedding

SCADA data collection

Generator control &

rotection

PlantPAx access to all

information and control from

a single interface


Integrating the Switch Yard with IEC 61850


In summary

PlantPAx is what I term “Whole Plant Control” Incorporates all of the essential systems into a single platform

DCS functionality HMI/SCADA, Plant operation Turbine and generator control Combustion control and burner management (HRSG) BOP Instrumentation APC Power Quality/Management - Switch yard and sub station


We care what you think!

On the mobile app:1. Locate session using

Schedule or Agenda Builder2. Click on the thumbs up icon on

the lower right corner of the session detail

3. Complete survey4. Click the Submit Form button

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Please take a couple minutes to complete a quick session survey to tell us how we’re doing.

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1

Thank you!!


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Questions?

Contact Information:Lee WardRegional Business ManagerEngineering Consultants774 249 [email protected]

plantpax: a "whole plant" control solution for power generation

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