PLC

&
DDCMIS
What is PLC?
Programmable
Logic
Controller

… a nice replacement
for electromechanical
relay controls
 What is PLC?
• A PLC is an industrially hardened computer-
based unit that performs discrete or
continuous control functions in a variety of
processing plant and factory environments.
• Originally intended as relay replacement
equipment for the automotive industry, the
PLC can be found in some part of virtually
every type of industry imaginable.
• The primary reason for designing such a
device was eliminating the large cost
involved in replacing the complicated relay
based machine control systems.
 What is inside a PLC?
PROGRAMMING
DEVICE

POWER SUPPLY CPU MEMORY

I/O BUS

I/O SYSTEM MODULES

OUTPUT INPUT
DEVICES DEVICES

SOLENOIDS SWITCHES
MOTOR STARTERS PUSH BUTTONS ETC
ETC
 What is inside a PLC?
Power Supply
It converts Power Line voltages to those required by electronic
components of PLC.
It may be Integral or separately mounted.
It provides the isolation necessary to protect electronic components
from most high-voltage line spikes.
It is rated for heat dissipation requirements for plant floor operation.
 What is inside a PLC?
Input Systems
Inputs are defined as real-world signals giving the controller real-time
status of process variables.
These signals can be analog or digital, low or high frequency,
maintained or momentary.
They are presented as a varying voltage, current or resistance value.
Signals from thermocouples and RTDs are common examples of
analog signals.
Pushbuttons, limit switches & electromechanical relay contacts are
familiar examples of digital, contact closure type signals.
 What is inside a PLC?
Outputs
 There are three common categories of outputs:
• Discreet: Pilot lights, solenoid valves, annunciator windows (lamp
box)
• Register: Panel meters or displays
• Analog: Variable speed drives or I/P converters (control valves)
 Most I/O systems are modular in nature; that is, a system can be arranged
by use of modules that contain multiples of I/O points.These modules can
be composed of 1, 4, 8, or 16 points and plug into the existing bus
structure.
 The bus structure is really a high-speed multiplexer that carries
information back and forth between the I/O modules and the CPU.
 One of the important functions of I/O is its ability to isolate real-world
signals from the low signal levels in the I/O bus
 What is inside a PLC?
Central Processor Unit
It performs the tasks necessary to fulfill the PLC function. Among
these tasks are
• Scanning
• I/O bus traffic control
• Program execution
• Peripheral & external device communications
• Self Diagnostics
One important factor which rates a PLC is scan time. It is roughly
defined as the time it takes for the PLC to interrogate the input
devices, execute the application program and provide updated signals
to the output devices.
 What is inside a PLC?
Memory Unit
It is the library where the application program is stored.
It is also where the PLC’s executive program is stored. An executive
program functions as the operating system of the PLC. It is the
program that interprets, manages and executes the user’s application
program.
It is the part of PLC where process data from the input modules and
control data for the output modules are temporarily stored as data
tables.
Memory can be volatile or nonvolatile. Volatile memory is erased if
power is removed. Battery backup is provided for most units with
volatile memory to avoid loss of program in the event of power outage.
 What is inside a PLC?
Programmer Unit
It provides an interface between the PLC and the user during
program development, start-up and troubleshooting.
The instructions to be performed during each scan are coded and
inserted into memory with the programmer.
Programmers vary from small hand-held units the size of a large
calculator to desktop stand-alone intelligent CRT-based units.
Programmers come complete with documentation, reproduction, I/O
status & on-line and off-line programming ability.
Many PLC use a PC as the programming tool using the serial
interface and a Programming Software.
 How a PLC Operates?
Step 1-CHECK INPUT STATUS-First the
PLC takes a look at each input to determine if
it is on or off. It records this data into its
memory to be used during the next step.
Step 2-EXECUTE PROGRAM-Next the PLC
executes your program one instruction at a
time using the input data obtained in previous
step and decides about the states of output. It
will store the execution results for use later
during the next step.
Step 3-UPDATE OUTPUT STATUS-Finally the PLC updates the
status of the outputs using the results obtained in previous step.

After the third step the PLC goes back to step one and repeats the
steps continuously.
 How a PLC is Programmed?
Ladder Diagrams
• Ladder diagrams are one traditional method of describing control
circuits.
• There are a few basic symbols that are used to express the meaning
and purpose of a control circuits. They are

Normally Open Starter/Relay/

Contact Solenoid Coil

Normally Closed Time Delayed

Contact Contact
(T.O.)
(Time to Open)
Normally Open
Push Button

Normally Closed
Push Button
 Example PLC Program
Let us consider a simple example. In the
given circuit, the coil will be energized
when there is a closed loop between the +
and - terminals of the battery(When both
the switches SW1 & SW2 are closed).
This simple circuit is represented in a
ladder Diagram as below. A ladder diagram consists of
individual rungs just like on a real
ladder. Each rung must contain one
or more inputs and one or more
outputs. The first instruction on a
rung must always be an input
instruction and the last instruction on
Some PLC require that every a rung should always be an output
ladder diagram include an END (or its equivalent).
instruction on the last rung.
 Advantages of PLC
Compared with electromechanical relay systems, PLCs offer the
following advantages:
 Ease of programming and reprogramming in the plant.
 A programming language that is based on relay wiring symbols
familiar to most plant personnel
 High reliability and minimal maintenance
 Small physical size
 Ability to communicate with computer systems in the plant
 Moderate to low initial investment cost
 Rugged construction
 Modular design
 PLC Applications at Our Project
Some of the areas using PLC are:
 Coal Handling Plant Stage-II
 Ash Handling Plant Stage-II
 DM Water Plant Stage-II
 Condenser Tube Cleaning System Stage-II
 Generator Stator Water Conductivity/Flow Protections Stage-I
 Boiler Feed Pump Delta-T Protection in Unit-II
 WHAT IS DDCMIS ?
DISTRIBUTED Distributed means there is no
DIGITAL centralized control and control
is spread across multiple units
CONTROL, Digital means processing of
process information is done in
MONITORING & digital form using micro-
processor based hardware
INFORMATION MIS interfaces the human with
process using computers
SYSTEM
 DDCMIS – TECHNOLOGICAL
BACKGROUND
PROGRESS OF INSTRUMENTATION USED TO IMPLEMENT
AUTOMATIC PROCESS CONTROL

• LOCAL PNEUMATIC CONTROLLERS

• MINIATURIZED AND CENTRALIZED PNEUMATIC
CONTROLLERS AT CONTROL PANELS AND CONSOLES

• SOLID-STATE CONTROLLERS

• COMPUTERISED CONTROLS (SUPERVISORY)

• DIRECT DIGITAL CONTROL(DDC)

• DISTRIBUTED MICROPROCESSOR BASED CONTROL

Why DDCMIS?
Disadvantages of earlier Systems
• Analog instrument panels required huge space, lot of
wiring and are less user friendly for monitoring of large
number of parameters.
• Accuracy obtained with solid-state controls is not good
and they tend to drift with time.
• Supervisory controls are inflexible as changing of control
configuration requires change in routing of wires.
• Use of centralized control leads to complete failure
during shutdowns.
Components of DDCMIS

MAN MACHINE INTERFACE & PROCESS

INFORMATION SYSTEM

DATA COMMUNICATION SYSTEM

( DATA HIGHWAY)

CONTROL SYSTEM
Components of DDCMIS
DATA COMMUNICATION SYSTEM
• LOCAL SYSTEM BUS – It is just lines on the backplane of
control panel to which all the modules are connected directly.
It serves as communication medium between the modules.
• INTRAPLANT BUS(IPB) – It is a coaxial cable which runs
through all the panels of control system and interconnects
them.
• LOCAL AREA NETWORK(LAN) – It is a network of
computers which are connected to a single point(HUB).
SOME FORM OF REDUNDANCY IS PRESENT
Components of DDCMIS
CONTROL SYSTEM
FUNCTIONAL DIVISION
• SG-C&I SYSTEM
• TG-C&I SYSTEM
• BOP-C&I SYSTEM

HARDWARE COMPONENTS
• POWER SUPPLY
• CONTROL PANEL
• ELECTRONIC MODULES
SG-C&I SYSTEM
CONSISTS OF
• BURNER MANAGEMENT SYSTEM (BMS)
• SOOT BLOWER CONTROL SYSTEM (SBC)
• SECONDARY AIR DAMPER CONTROL SYSTEM (SADC)
• AUXILIARY PRDS CONTROLS (APRDS)
• HP BYPASS SYSTEM(HPBP)
TG-C&I SYSTEM
CONSISTS OF
• ELECTRONIC TURBINE PROTECTION (ETP)
• AUTOMATIC TURBINE RUN-UP SYSTEM (ATRS)
• AUTOMATIC TURBINE TESTING SYSTEM (ATT)
• ELECTRO- HYDRAULIC TURBINE CONTROL SYSTEM (EHTC)
• TURBINE STRESS CONTROL SYSTEM (TSC)
• LP BYPASS SYSTEM (LPBP)
• GLAND STEAM PRESSURE CONTROL
• GENERATOR AUXILIARY MONITORING PANEL (GAMP)
 BOP-C&I SYSTEM
• CONSISTS OF OPEN LOOP CONTROL SYSTEM (OLCS) AND CLOSED
LOOP CONTROL SYSTEM (CLCS)

• OLCS - THE SEQUENCE CONTROL, INTERLOCK OF ALL THE PLANT

SYSTEMS WHICH ARE NOT COVERED IN THE SG-C&I AND TG-C&I.
THIS INCLUDES MAJOR AUXILIARIES LIKE FD/ID/PA FANS, AIR-
PREHEATER, BFP/CEP/CWP/ BCWP , DMCWP/CLCWP AND
ELECTRICAL BREAKERS.
• CLCS - THE MODULATING CONTROL FOR VARIOUS IMPORTANT
PLANT PARAMETERS, LIKE FW FLOW (DRUM LEVEL), FURNACE
DRAFT, COMBUSTION CONTROL (FUEL FLOW AND AIR FLOW), PA
HDR PRESSURE CONTROL, DEAERATOR/HOTWELL/HEATER LEVEL
CONTROLS ETC.
CONTROL SYSTEM - HARDWARE
THE CONTROL SYSTEM USED IN STAGE-II IS
PROCONTROL P13/42
PROCONTROL MODULES
• INPUT
• OUTPUT
• PROCESSOR
• DRIVE
• BUS COMMUNICATION
CONTROL SYSTEM - HARDWARE
INPUT MODULE

It receives the process signal, convert them to digital

form and communicate the value on local bus

• ANALOG
– Voltage(EA01) 4-channel
– Current(EA02) 4-channel
– RTD(EA03) 4-channel
– Thermocouple(EA04) 8-channel

• DIGITAL
– Voltage(EB01) 4-channel
– Single contact(EB02) 16-channel
– Change-over contact(EB03) 5-channel
CONTROL SYSTEM - HARDWARE
OUTPUT MODULES

They receive the value from localbus and give output to

the process/field.

• ANALOG
– Voltage(AA01) 4-channel
– Current(AA02) 4-channel

• DIGITAL
– Voltage(AB01) 16-channel
– Contact(AB02) 16-channel
CONTROL SYSTEM - HARDWARE
PROCESSOR MODULE ( PR05)

• IT IS RESPONSIBLE FOR THE EXECUTION OF ALL THE

LOGICS THAT IS PROGRAMMED INTO IT
• IT CAN BE USED IN REDUNDANT MODE
• IT IS PROGRAMMED USING SK06 KIT, WHICH IS A
COMPUTER BASED UNIT FOR INTERFACING WITH
PROCESSOR
• THE LOGICS ARE PROGRAMMED USING THE P10 LANGUAGE
CONTROL SYSTEM - HARDWARE
DRIVE MODULES

• THESE ARE USED FOR CONTROLLING THE DIFFERENT

TYPES OF PROCESS ACTUATING ELEMENTS
• THEY HAVE PREDEFINED LOGICS BUILT INTO THEM
• TYPES
– ANALOG (AS06)
• USED FOR DRIVING ANALOG CONTROL DRIVES SUCH AS
VARIABLE SPEED DRIVES, CONTROL VALVES THROUGH I/P
CONVERTER ETC
– DIGITAL (AS04)
• USED FOR OPERATING MOTORS, ELECTRICAL VALVES,
SOLENOID VALVES ETC
CONTROL SYSTEM - HARDWARE
BUS/COMMUNICATION MODULES
BUS TRAFFIC DIRECTOR
• IT CONTROLS THE COMMUNICATION PROCESS ON THE BUS
- THERE ARE TWO TYPES OF TRAFFIC DIRECTORS:
– LOCAL BUS(BV05)
– INTRAPLANT BUS(FV05)

BUS COUPLER(BK02)
• IT CONNECTS THE LOCAL BUS TO THE IPB
BUS END MODULE(BA01)
• IT IS USED FOR TERMINATING THE LOCAL BUS
 LOCAL BUS – P42
IPB Analog Binary
PROCESSOR
Input Input
Module Module

Bus Local Bus

Coupler

AD CLK

DRIVE LOCAL
Analog Binary
CONTROL BUS
Output Output
MODULE TRAFFIC
Module Module
DIRECTOR
CONTROL SYSTEM OVERVIEW

IPB - 1

WSPOSE
IPB BUS BUS
PANEL
TRAFFIC COUPLER COUPLER
DIRECTOR
Local Bus
Local Bus -1.0B
-1.0C,2.0C
SERVER
BUS
COUPLER
IPB - 2

IPB BK 02
TRAFFIC
DIRECTOR Local Bus -1.0C
 Components of DDCMIS
MMIPIS – MAN MACHINE INTERFACE & PLANT INFORMATION

SYSTEM
Functions
• VPC OPERATION
• OTHER OPERATOR INFORMATIONS THROUGH VARIOUS
DISPLAYS
• ALARMS, LOGS, HISTORICAL AND LONG TERM STORAGE.
• PERFORMANCE AND OTHER CALCULATIONS

PMS AND WSPOSE ARE EXAMPLES OF MMIPIS SYSTEM

 WSPOSE OVERALL VIEW
PS PS

PR O/P PR05

LOCAL BUS STATIONS

I /P I /P O/P I /P I /P O/P

BK BK
IPB 1 & 2

WS POSE PANEL ( DDC – MMI INTERFACE PANEL )

SERVER 1 SERVER 2

LAN

OWS 1 OWS 5
 OWS -1 OWS -2 OWS -3 OWS -4

WORKSTATIONS
PMS PANEL
LAN
SERVER2 SERVER1 PMS
IPB
SYSTEM
ACCESS
COUPLER

STATION
SG PACKAGE TG PACKAGE
C&I

IPB - 1

IPB - 2

IPB - 3

IPB - 4
 WHY DDCMIS ?
1. VERY HIGH FLEXIBILITY FOR MODIFICATION
IN CONTROL STRATEGY
2. VERY HIGH SELF-DIAGNOSTIC
3. VERY LOW DRIFT (ONLY IN I/O CARDS) ,
HENCE NO NEED OF FREQUENT RE-
CALIBRATION
4. MUCH HIGHER RELIABILITY (BASED ON
MTBF)
5. BETTER LONG TERM SUPPORT DUE TO
CHANGING TECHNOLOGY
6. MUCH BETTER OPERATOR INTERFACE
 PLC & DDC - COMPARISION

• DCS systems are used for large applications and closed loop
controls, whereas, PLC are primarily used for small applications
and sequential controls.
• DCS systems are very costly for small applications, whereas,
PLCs are much cost-effective for both small and large
applications.
• While DCS systems are superior in communication redundancy
and data security, PLCs are better for logic, are faster and have
more rugged I/O.
• DCS systems are more difficult to design than PLCs.
SALIENT FEATURES OF
DDCMIS
SALIENT FEATURES OF DDCMIS

• INTEGRATED PLANT CONTROL FOR SG,

TG AND BALANCE OF PLANT CONTROL IT
MAY BE REMEMBERED THAT HISTORICALLY THE
TERM DDCMIS USED BE REFERRED TO FOR THE SO-
CALLED “BOP-C&I” . THE SG-C&I, i.e. FSSS etc. TG-
C&I i.e. ATRS, TURBINE PROTECTION etc.
ORIGINALLY WERE NOT CONSIDERED UNDER
DDCMIS OR DCS AS PER MANY SUPPLIERS. ONLY
RECENTLY THE TYPE OF SYSTEMS FOR ALL THE
SYSTEMS HAVE BECOME SIMILAR (WITH SOME
DIFFERENCE WHICH WILL BE DISCUSSED LATER), WE
TEND TO CONSIDER THESE SYSTEMS UNDER
DDCMIS.
SALIENT FEATURES OF DDCMIS

• INTEGRATED PLANT OPERATION

THROUGH FULLY INTERCHANGEABLE
OPERTAOR WORK STATIONS (OWS) FOR
SG, TG AND BALANCE OF PLANT
(SOMETIMES THIS MAY NOT BE POSSIBLE DUE
TO PACKAGING CONCEPT)
SALIENT FEATURES OF DDCMIS

• PROVISION OF EXTENSIVE SELF-

DIAGNOSTICS
• USE OF LARGE VIDEO SCREENS FOR
PROJECTIONS OF VARIOUS PLANT MIMICS
ETC.
• PROVISION OF FAULT ALARM ANALYSIS
TO GUIDE THE OPERATOR TO THE MOST
LIKELY EVENT
• PROVISION OF TREND ALARMS
SALIENT FEATURES OF DDCMIS

• PROVISION OF SAFETY HARDWARE FOR

BURNER MANAGEMENT SYSTEMS

• PROVISION OF FAIL-SAFE HARDWARE FOR

TURBINE PROTECTION SYSTEM

• PROVISION OF ADEQUATE RELIABILITY

AND AVAILABILITY WITH PROPER
REDUNDANCY IN SENSOR, I/O AND
CONTROLLER LEVELS.
DDCMIS CONFIGURATION

maxDNA
SYSTEM
ENGG. STN
HMI
FOR HMI

PROCONTROL MMI LAN

SYSTEM
HMI
REDUNDANT
SERVERS
ENGG.STN.
FOR CONTROL SYS. I.P. BUS Max. 4
nos. rdundant

Redundant
F.G.Controllers

Measurement system / I/O

subsystem
CONTROL SYSTEM
 CONTROL SYSTEM
PROGRAMMING & MMIPIS M&S
CONFIGURATION SYSTEM CLOCK

DCS

SG- C&I BOP- C&I TG- C&I

SYSTEM SYSTEM SYSTEM
DCS

2 X 100 %
CONTROLLERS
(INCL. COMM. CONT.)

LOCAL BUS

I/O CARDS DCMS **

FUNCTIONAL GROUPS
• SIGNIFICANT REDUCTION IN
NUMBERS EXPECTED IN
FORTHCOMING PROJECTS
• COMBINING OF OLCS AND CLCS
CONTROLLERS - HISTORICAL
BACKGROUND
• EXCEPT FOR CERTAIN SUPPLIERS, ALL
HAVE VERY POWERFUL CONTROLLERS
• TRANSPARENCY 6,7,8 FOR GROUP DRAWINGS
MMIPIS
 MAN-MACHINE INTERFACE AND
PLANT INFORMATION SYSTEM

• LATEST STATE-OF-THE-ART WORKSTATIONS AND

SERVERS BASED ON OPEN-ARCHITECTURE AND
INDUSTRY STANDARD HARDWARE AND SOFTWARE
TO ENSURE BETTER CONNECTIVITY.
• e.g. HARDWARE FROM COMPAQ/DIGITAL, HP, SUN
MICRO-SYSTEM OR OTHER MAJOR SUPPLIERS (LESS
DEPENDENCE ON THE C&I SYSTEM SUPPLIER IN THE
LONG RUN)
• OPERATING SYSTEM WINDOWS-NT, OPEN-VMS OR
UNIX.
MAN-MACHINE INTERFACE AND
PLANT INFORMATION SYSTEM
• 64-BIT SERVER/OWS WITH HIGH-SPEED AND
LARGE MEMORY (256/512 MB RAM, 8 GB HDD
FOR SERVER AND 128/256 MB RAM AND 4/6 GB
HDD FOR OWS) TO ENSURE FAST RESPONSE
• PROVISION OF LVS
• CONNECTION TO OTHER SYSTEM THROUGH
STATIONWIDE WAN
• TRANSPARENCY NO 9 & 10
MMIPIS FUNCTIONALITIES

• VPC OPERATION
• OTHER OPERATOR INFORMATIONS
THROUGH VARIOUS DISPLAYS
• ALARMS, LOGS, HISTORICAL AND LONG
TERM STORAGE.
• PERFORMANCE AND OTHER
CALCULATIONS
DCS
REDUNDANT DATA
COMMUNICATION SYSTEM (DCS)

• 1. MAIN SYSTEM BUS

• 2. LOCAL SYSTEM BUS
• 3. LOCAL BUS OR I/O BUS
• 4. OWS LAN
• 5. STATION-WIDE WAN
DDCMIS CONFIGURATION

maxDNA
SYSTEM
ENGG. STN
HMI
FOR HMI

PROCONTROL MMI LAN

SYSTEM
HMI
REDUNDANT
SERVERS
ENGG.STN.
FOR CONTROL SYS. I.P. BUS Max. 4
nos. rdundant

Redundant
F.G.Controllers

Measurement system / I/O

subsystem
 OFF-LINE LAN

GATEWAY TO CORP.
CENTRE
STATION-WIDE ON-LINE LAN

UNIT C&I OFF-SITE C&I

OTHER
SYSTEM SYSTEM
UNITS
(TYP)
(TYP)
 POWER SUPPLY SYSTEM

• CONTROL SYSTEM POWER SUPPLY TWO SETS

OF DC POWER SUPPLIES - ONE SET FOR SG/TG-
C&I AND OTHER FOR BOP-C&I EACH WITH 2 X
100 % CHARGER AND 2 X 100 % BATTERY.
• OTHER IMPORTANT AC LOADS LIKE MMIPIS,
PANEL INSTRUMENTS, ANALYSERS ETC. SHALL
BE POWERED FROM UPS COMPRISING OF 2 X
100 % CHARGER, 2 X 100 % INVERTER AND 1 X
100 % BATTERY.
• HEAVY DUTY Ni-Cd BATTERIES HAVE BEEN
ENVISAGED FOR LONGER LIFE & LESSER
MAINTENANCE
 CABLING & TERMINATION

• EXTENSIVE GROUPING OF SIGNALS BY LARGE

SCALE USE OF JBs AT STRATEGIC LOCATIONS
• USE OF CABLES WITH HIGHER NO OF PAIRS
• USE OF MAXI-TERMI CONNECTION FOR SYSTEM
CABINETS, MARSHALLING PANELS & OUTGOING
SIDE OF JBs, CJS BOXES etc.
• USE OF PLUG-IN SOCKET AND CONNECTORS
FOR TRANSMITTERS, SWITCHES, LS/TS etc.
 IMPORTANT SG/TG RELATED C&I SYSTEM

• FLAME MONITORING SYSTEM

• COAL FEEDER C&I
• ELECTROMATIC SAFETY VALVES
• FURNACE TEMP PROBES
• ACCOUSTIC PYROMETER FOR FURNACE TEMP PROFILE
• BOILER FLAME ANALYSIS SYSTEM
• COAL BUNKER LEVEL MONITORING SYSTEM
• ELECTRONIC DRUM/SEPARATOR LEVEL MONITORING
SYSTEM
• TURBINE SUPERVISORY SYSTEM
• TDBFP TURBINE SUPERVISORY SYSTEM

• IN PACKAGED SYSTEM, THESE ARE UNDER

SG & TG PACKAGES.
 SCOPE OF SUPPLY OF C&I SYSTEM
• DDCMIS (IN C&I PACKAGE, SG-TG C&I & ASSOCIATED
MMI etc. EXCLUDED)
• OTHER SG/TG C&I (ONLY FOR TURN-KEY PACKAGE)
• MEASURING INSTRUMENTS
• SWAS
• CONTROL DESK/PANELS
• ALARM ANNUNCIATION
• ELECTRIC POWER SUPPLY
• CONTROL VALVE AND ACTUATORS (ONLY FOR 500 MW
PROJECTS, BEING DELETED FROM C&I IN RECENT
PROJECTS)
• MAINTENANCE & CALIBRATION EQUIPMENT
• INSTRUMENTATION CABLES
• PROCESS CONNECTION & PIPING
• PA SYSTEM
• OFF-SITE PLANT CONTROL SYSTEM (ONLY FOR TURN-
KEY PACKAGE, ELSE IN RESPECTIVE MECH. PKG)
 OPERATION PHILOSOPHY
• CENTRALISED OPERATION OF MAIN PLANT THROUGH OWS
& LVS
• OFF-SITE PLANTS TO BE CONTROLLED FROM THEIR LOCAL
STATIONS WITH STATION-WIDE LAN DATA LINK
• MINIMUM BACKUP INSTRUMENTATION ( ORIGINALLY
CONSERVATIVE, NOW REDUCED. CRITERIA - HANDLING
EMERGENCY & SAFE SHUT-DOWN)
• GEOGRAPHICAL DISTRIBUTION - ALTHOUGH NOT VERY
USEFUL FOR POWER PLANTS AS COMPARED TO
PROCESS/INDUSTRIES, BEING ADOPTED FOR FEW AREAS
WHERE SIGNALS ARE CONCENTRATED (REDUCTION OF
CABLING, MUCH LESS ERECTION & COMMISSIONING TIME)
 REDUNDANCY
• IN CONTROL SYSTEM
– ORIGINALLY THE CONTROLLERS
– ALT-I - SINGLE LOOP NON-RED
– ALT-II- MULTI-LOOP REDUNDANT
– NOW ALT-I ABOLISHED. NOW 2 X 100 % OR 2 OUT OF 3.
• I/O REDUNDANCY - CURRENT PROJECTS HAVE HIGH LEVEL
OF I/O & DRIVE CONTROL MODULES REDUNDANCY DUE TO
LOWERING OF BACK-UP AND INCREASE IN NO. OF
CHANNELS. IN FUTURE PROJECTS, LIMITED TO SAFETY
SYSTEMS AND CASES WHERE SENSOR REDUNDANCY IS
THERE.
• DATA COMMUNICATION SYSTEM - 100 % REDUNDANT
• MMIPIS
– - REDUNDANT SERVERS
– MULTIPLE OWS (PRESENTLY 10 NOS, BEING REDUCED TO 6 NOS.)
 DESIGN CRITERIA
• PROVENNESS
– SUPPLIER’S EXPERIENCE
– SYSTEM EXPERIENCE
– PROVENNESS VS OBSOLESCENCE
• RELIABILITY AVAILABILITY
– HARDWARE QUALITY (PUBLISHED MTBF etc.)
– CONFIGURATION
– REDUNDANCY
– FAULT TOLERANCE
• STANDARDISATION AND UNIFORMITY OF H/W
– SAME SERIES & FAMILY OF H/W AS FAR AS POSSIBLE
– DIFFICULTIES BECAUSE OF PACKAGING CONCEPTS & RESPOSIBILITY
CENTRE & INTERFACES (EVEN IN TURNKEY PACKAGE)
 DESIGN CRITERIA
• OPERABILITY
– DESIGN CONCEPT - FAIL SAFE ETC.
– FALSE TRIP VS SAFETY
– OPERATOR CONVENIENCE DURING NORMAL RUNNING &
EMERGENCY
– MANAGEMENT REPORTING

• MAINTAINBILITY
– STANDARDISATION (AS INDICATED ABOVE)
– MODULAR DESIGN AND EXPANDABILITY
– DIAGNOSTIC, FAULT IDENTIFICATION AND FAULT TOLERANCE
– GUARD AGAINST OBSOLESCENCE
– AVAILABILTY OF SPARES
• OTHER CRITERIA
– UNIT OPERATION PHILOSOPHY
– MARKET TRENDS AND EVOLUTION OF INFORMATION TECHNOLOGY
– FEEDBACKS FROM EXISTING SYSTEMS