maxDNA Overview PDF

ELECTRONICS DIVISION, BANGALORE
maxDNA
Dynamic Network of Applications
…… the Industry Standard Process Control and
Enterprise Management System
Plant--wide Unified Automation Solution…….

Plant
CE/MKTG/EDN : July:2007
CE/MKTG/MGK/EDN Jan 2006
TOTAL CONTROL SOLUTIONS
Power
Installed base in...
Chemicals - India
• Fossil fired power
plants - coal, oil and
gas, combined cycle
• Cogeneration plants
• Hydro Power Plants
• Cement, Glass &
Ceramics
Petroleum - Brazil
• Primary Metals
• Chemicals
• Petroleum
• Water & Wastewater
Treatment
• Incineration
Hydro Power
CE/MKTG/EDN : July 2007

System introduction… Control level
Distributed
Processing Unit
(DPU)
System 24V
I/O Bus
8 pack rack Connector
I/O Bus
Connectors
Field 48V
(DPU4F and I/O) Field 24V
I/O Modules Eight-pack rack
D I I I
Remote Processing P O O O
I/O signals
Unit (RPU)…….. D
P
I
O
I
O
I
O
U
System Cabinets
I I I I
O O O O

HMI …... maxSTATIONS – Generic

name for ….
Operator Stations
maxVUE Workbench
Engineering Station
maxSTORIAN
Remote maxVUE
maxLINKS
maxDNA
maxNET • GT Controls
• TSI
100 Mbps (full • PLCs
• Numerical Relays
duplex) • External systems
• IEEE802.3u
REMOTE maxVUE
Plant information network
maxSTATIONS
ENGINEER’S
STATION / maxSTORIAN
Redundant 100 Mbps maxNET
maxLINK
FIBRE OPTIC
LINK
REMOTE PROCESSING UNITS (RPUs)
PLANT SUB-SYSTEMS
TYPICAL CONFIGURATION DIAGRAM
REMOTE I/O
• Serverless Configuration • Scalable…as large as required

Modular Architecture
• Plug and Play System Additions
• Can Grow as Your Needs Change
maxVUE maxTOOLS History Reports Firewall Applicat.
Software Backplane
Provider PLC DPU 4F
Turbine Governing, BMS …..to Plant-

Plant-wide Automation

UNIFIED SOLUTION FROM BHEL

CCPP / CO-GEN PLANTS
THERMAL PLANTS • HRSG Controls
• Boiler Controls • Steam Turbine Controls
• Turbine Controls • Station C&I
• Station C&I
• HMI
• HMI
• Interface to GT
• Power Plant SCADA
• Power Plant SCADA
HYDRO PLANTS
• Computerised Control &
Monitoring System Governor
Controls
• Remote Operation
• HMI
• Optimisation Packages

Large Video Screen (Optional)

Remote maxVUE
(Optional)
NETWORK PRINTERS
:
DMP x 3
Operator Operator Operator Peformance ENGG.
Station # 1 Station # 2 Station # n Calcs. Station maxSTORIAN STATION
… STATION A4 - COLOR
INKJET x 1
…
CD R/W A3 - COLOR
INKJET x 1
UNIT CONTROL DESK
(minimum/trip related)
ETHERNET SWITCH
PB STN (TRIP). maxLINKS
maxNET
ETHERNET SWITCH RPUs (I/O + DPU + Network Components)
RPU RPU RPU RPU RPU RPU RPU

RPU RPU
RPU
DPU DPU DPU DPU DPU DPU DPU DPU
… … … … I/O Modules
I/O Modules I/O Modules I/O Modules I/O Modules I/O Modules I/O Modules I/O Modules
FG # Turbine FG # Boiler FG # STN. C&I +ELECT. SWITCH YARD SCADA
LOCAL JB LOCAL JB CJC BOX LOCAL JB LOCAL JB

~
+
- E POWER MOTORS
P AMP.
T/Cs RTDs PUMPS/
ANALOG MOTORISED BREAKERS
CONTACT (4-20mA) VALVES/
INPUTS DAMPERS
Turbine Governing, BMS …..to Plant-

Plant-wide Automation
Distributed Processing Unit

• 32 Bit Processor
• Redundant / Stand-alone modes
• Windows CE.net Operating System
• Open architecture
• Dual ethernet ports, to maxNET
• Dual 100 Mbps highway connections for high
speed – NO intermediate servers /
communication modules
• Network hardened to withstand problems
• Optional IRIG input for satellite time
synchronization
• High temperature tolerance and low power -
No fans, no batteries for low maintenance,
high reliability

Distributed Processing Unit

• 128 MByte RAM
• 64 MByte Removable Compact Flash
• Non-volatile FLASH memory maintains the control
strategy configuration even if power is lost
• Modulating Control, Logic, Data Acquisition
• 8,500 function blocks for high capacity complex
control
• Event Reporting to 1 msec Resolution
• User configurable program execution time
between 10 msec - 500 msec (best use of the
processor)
• 10,000 event queue
• Directly accessible from all maxSTATIONS
• Object-Oriented Configuration (totally name based)
• Supports off-line simulation and testing

DPU Processing Capability

• Multiple time classes - TX FT FT
10 msec to 500 msec
• Sequence-of-Events to
1 msec resolution for X X
500 discrete inputs
• Quality coding - Good, ∆
bad, doubtful, and
substitute D1
D2
OR AND FT X ∆
• Quality code is PID
D3
propagated throughout OR
the system so that trend D4 Σ
and archive data can
also include quality
codes.
• Modulating control,
logic processing, and
data acquisition

DPU Redundancy
maxNET
Parallel
I/O Bus
• Primary and secondary are selected through

configuration
• Fatal diagnostic error causes transfer in <3 msec
• Secondary DPU configuration can be modified and
transfer initiated for testing purposes
maxPAC I/O…
comprehensive line of
I/O modules
• Surface mount electronics - compact, reliable, efficient

• Surge withstand as per IEEE 472-1974
• RFI and EMI per IEC 61000-4-2, 3 & 12
• ADC resolution 15 bits + sign
• Self calibrated analog modules
• 500V peak AC or DC Common mode voltage protection
• Status indication LED for each channel
• Redundant configuration possible for both analog and digital I/O

maxPAC I/O…. saves time

and money
• Module and field instrument power is bused to each module through the
I/O rack back-panel
• No need for fuses - individual channels have self resetting electronic
fuses or current limiting input circuits
• No special tools required for service
• Hot swap of I/O modules permitted
• No damage if modules are inserted in incorrect slot
• Very low power requirements
• Maximum addresses per maxDPU4F is 255
• Each analog card is 2 addresses and each digital card is 1 address.
maxPAC …..
same modules used for
remote and local I/O
• Bus Extender Module (BEM) for remote I/O

• Maximum 2000 mts and FO cables are standard
• Redundant communication
• SOE points can be remote
• Same modules used for remote and local I/O
• Remote I/O performs just like local I/O
• Identical I/O means lower investment in spare parts
I/O Redundancy
I/O Can be Redundant ...
I/O I/O
I/O I/O
I/O I/O ... And Shared

Redundant
DPU Bus

maxSTATION
• True open system architecture
• Seamless communications with plant and
business networks
• Scaleable from small process applications
to complete plant control
• On-line graphic monitoring
• On-line Self-documenting configuration
• Ultra high speed graphic building and
display updates
• Clear Graphic displays, with animations
powered by maxSCRIPT
• Popup windows for all tagged standard objects
• Track select point facility
• Centralised Engineering capability

Windows XP
• Standard Operating System for all maxSTATIONS

• Largest base of software applications
• Strongest standards for compatibility
• High reliability and security
• Easily upgraded
• Latest intuitive windows interface for easy
operator training and use
• New suite of functions

maxVUE Editor Object Oriented

Comprehensive graphical Fast to learn due to industry
symbol library standard look-and-feel
Supports re-use of
graphical objects
Uses Active-x
components, bmp
For the advanced user …… Powerful

• Visual Basic OCX objects maxSCRIPTS
• Visual C++ OCX objects
• Third party OCX
Endless wealth of options……

…... Robust…..Elaborate programming is avoided
Typical Graphical Display

Typical DPU download
IP address of DPU
Primary DPU Active

Secondary DPU Inactive
& Running
& Running
configuration
down loading to DPU: Processing Bar

DPU Over Run Criteria

Graphical Configurator
for Application Building and Testing
• Integrated analog and digital controls
• Both graphical and database tools
• Clear application
testing and
debugging

Two Tools with Complementary Functions

maxTOOLS maxVUE
Database-
Database-oriented Graphical Configurator
• Define DPUs & I/O modules • Connects to a DPU – Real or Virtual

• Create & edit configurations off-line • Fully self-describing DPU – no off-
• Download & upload configurations to line storage of database or diagrams
Real or Virtual DPUs is required for 100% documentation
– Full or Incremental
• Create & edit logic diagrams
• Import & export configuration data
from a database – Access, etc. • Copy & paste function blocks
• Display & print logic diagrams
Configuration Management
• Database reports & queries Testing - Tuning
• Compare configuration files • Browse configurations on-line
– off-line or on-line vs. off-line • Edit function block connections,
• Update database versions parameters, descriptions, etc. on-line
• Add/delete function blocks on-line
• Save configuration files off-line
• Edits are protected by security

maxSTORIAN
• Historical Data Collection and Archiving
Software for maxSTATION
• “Delta-Save” data storage maximizes
system data capacity
• Events (alarms & events), trends, reports
• Time and event based report triggering
• Relational database to simplify reports and
queries for data analysis
• Archival storage to CD-ROM
• Supports interface to plant-management
networks
• Windows-XP based

maxLINK
maxNET • Interface to external systems: GTC, TSI, PLC
networks (Coal Handling Plant, Ash Handling
Plant etc.), Numerical relays, external
systems
• LDC Interface
• Supports multiple simultaneous
communication protocols
• Supports data transfer from other systems
and networks
• Provision in DPUs also
• All data available to maxSTATIONS
Plant Sub-Systems • Windows-XP based
• Software Backplane® compatible

maxNET Communications Network
• Proven Industry Standard, Switched Fast Ethernet

• Ultra high speed (100 Mbps) redundant network
• Multiple simultaneous communication
• Utilises intelligent switching
• No collisions occur. Traffic is never stopped

Inter-Hub Communications
Full Duplex Switched Hub Full Duplex Switched Hub
100 Megabits per Second

Full Duplex
• All standard communication media supported -

Fiber optic and UTP
• Future Gigabit and high communications rates

Network Failover
Switch A
Network A
Network “MAP”
from Station 1
1 2 3
Station A B
2 OK OK
3 X OK
Network B
Switch B
• WorkStation 1 hears messages from station 2 on networks A and B.

• WorkStation 1 hears messages from station 3 only on network B.
• WorkStation 1 knows that it can talk to station 2 on either network A or
B, but it must use network B to talk to station 3.
• WorkStation 1 generates an alarm to notify the Operator.
• Network B is used for messages

Network Domains
maxSTATIONS maxSTATIONS
Switched
Hub
RPUs RPU
maxSERVER
• Global access of data for data acquisition and control
• Separates discrete sections of DCS - e.g. plant units
• Provides security and assures performance
• Simplifies maintenance
• Allows integration of other systems


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ELECTRONICS DIVISION, BANGALORE

Plant--wide Unified Automation Solution…….

CE/MKTG/EDN : July 2007

System introduction… Control level

(DPU4F and I/O) Field 24V

I/O Modules Eight-pack rack

CE/MKTG/EDN : July 2007

HMI …... maxSTATIONS – Generic

Plant information network

Redundant 100 Mbps maxNET

TYPICAL CONFIGURATION DIAGRAM

CE/MKTG/EDN : July 2007

maxVUE maxTOOLS History Reports Firewall Applicat.

Provider PLC DPU 4F

Turbine Governing, BMS …..to Plant-

CE/MKTG/EDN : July 2007

UNIFIED SOLUTION FROM BHEL

CE/MKTG/EDN : July 2007

Large Video Screen (Optional)

ETHERNET SWITCH RPUs (I/O + DPU + Network Components)

RPU RPU RPU RPU RPU RPU RPU

DPU DPU DPU DPU DPU DPU DPU DPU

FG # Turbine FG # Boiler FG # STN. C&I +ELECT. SWITCH YARD SCADA

LOCAL JB LOCAL JB CJC BOX LOCAL JB LOCAL JB

Turbine Governing, BMS …..to Plant-

Distributed Processing Unit

CE/MKTG/EDN : July 2007

Distributed Processing Unit

CE/MKTG/EDN : July 2007

DPU Processing Capability

CE/MKTG/EDN : July 2007

• Primary and secondary are selected through

• Surface mount electronics - compact, reliable, efficient

CE/MKTG/EDN : July 2007

maxPAC I/O…. saves time

• Bus Extender Module (BEM) for remote I/O

I/O I/O ... And Shared

CE/MKTG/EDN : July 2007

CE/MKTG/EDN : July 2007

• Standard Operating System for all maxSTATIONS

CE/MKTG/EDN : July 2007

maxVUE Editor Object Oriented

For the advanced user …… Powerful

Endless wealth of options……

Typical Graphical Display

Typical DPU download

Primary DPU Active

CE/MKTG/EDN : July 2007

DPU Over Run Criteria

CE/MKTG/EDN : July 2007

CE/MKTG/EDN : July 2007

Two Tools with Complementary Functions

• Define DPUs & I/O modules • Connects to a DPU – Real or Virtual

CE/MKTG/EDN : July 2007

CE/MKTG/EDN : July 2007

CE/MKTG/EDN : July 2007

maxNET Communications Network

• Proven Industry Standard, Switched Fast Ethernet

CE/MKTG/EDN : July 2007

100 Megabits per Second

• All standard communication media supported -

• Future Gigabit and high communications rates

CE/MKTG/EDN : July 2007