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EDPF-NT
Distributed Control System
EDPF-NT Distributed Control System
1
Contents
CHAPTER I OUTLINE OF EDPF-NT DISTRIBUTED CONTROL SYSTEM .......................................... 1
1.1. DEVELOPMENT HISTORY OF EDPF-NT .................................................................................................... 1 1.2 PRIMARY STANDARDS AND CODES OF SYSTEM .......................................................................................... 2 1.3 MAIN TECHNICAL FEATURES OF EDPF-NT ................................................................................................ 3 1.4 MAIN PERFORMANCE INDEX OF EDPF-NT ................................................................................................ 7 1.5 SEVERE QUALITY ASSURANCE MEASURE ................................................................................................... 8
CHAPTER II STRUCTURE AND BASIC FRAME OF EDPF-NT ........................................................... 10
2.1 STRUCTURE OF EDPF-NT ....................................................................................................................... 10 2.2 LAYERED MULTI-DOMAIN NETWORK COMMUNICATION SYSTEM ............................................................... 11 2.3 DISTRIBUTED PROCESS CONTROL STATION (DPU) ................................................................................. 12 2.4 ENGINEER STATION (ENG)....................................................................................................................... 13 2.5 OPERATOR STATION (OPR) ..................................................................................................................... 13 2.6 HISTORY DATA RECORDING STATION (HSR) ............................................................................................ 14 2.7 REPORT STATION (LOG) .......................................................................................................................... 14 2.8 PERFORMANCE COMPUTER STATION (CAC) ............................................................................................ 14 2.9 MULTI-FUNCTION INTERFACE WORKSTATION (GATEWAY) .................................................................... 14
CHAPTER III NETWORK INFORMATION TECHNOLOGY AND SAFETY MANAGEMENT AND
CONTROL PLATFORM OF MASSIVE WHOLE STATION INTEGRATED CONTROL SYSTEM ...... 15
3.1 NETWORK INFORMATION TECHNOLOGY OF MASSIVE WHOLE STATION INTEGRATED SYSTEM ................. 15 3.2 SAFETY MANAGEMENT AND CONTROL PLATFORM .................................................................................... 18
CHAPTER IV MONITORING AND OPERATING SOFTWARE OF EDPF-NT ..................................... 20
4.1 MULTI-WINDOW DISPLAY MODE ................................................................................................................ 21 4.2 TREND DISPLAY AND GROUP DISPLAY ...................................................................................................... 23 4.3 PROCESSING ALARM INFORMATION .......................................................................................................... 24 4.4 PNTBROWSER ........................................................................................................................................... 25 4.5 ALGORITHM BROWSER .............................................................................................................................. 27 4.6 HISTORY TREND BROWSER ....................................................................................................................... 28
CHAPTER V ENGINEER STATION SOFTWARE OF EDPF-NT ........................................................... 29
5.1 PROJECT ORGANIZER (PO) INTEGRATING DEVELOPMENT STYLE ........................................................... 29 5.2 GRAPHIC CONTROL CONFIGURATOR ........................................................................................................ 30
CHAPTER VI STORAGE AND RETRIEVAL OF HISTORY DATA, ALARM INFORMATION AND
EVENT INFORMATION ................................................................................................................................... 33
CHAPTER VII REPORT FUNCTION .......................................................................................................... 34
CHAPTER VIII LAYERED COMPREHENSIVE ON-LINE SELF-DIAGNOSTICS ............................... 35
CHAPTER IX DISTRIBUTED PROCESS CONTROL STATION (DPU) ............................................... 36
9.1 DPU CONTROLLER ................................................................................................................................... 36 9.2 SMART I/O MODULES ................................................................................................................................ 39
CHAPTER X FIELDBUS TECHNOLOGY OF EDPF-NT ......................................................................... 65
10.1 TECHNICAL POINTS OF EDPF-NT FIELDBUS ......................................................................................... 65 10.2 FIELDBUS ACCESS PLAN OF EDPF-NT SYSTEM .................................................................................... 65 10.3 PROFIBUS FIELDBUS ACCESS SCHEMES ............................................................................................. 67 10.4 EDPF-NT FIELDBUS EQUIPMENT MANAGEMENT SOFTWARE ................................................................ 69 10.5 SUMMARY ............................................................................................................................................... 73
CHAPTER XI OTHER PRINCIPAL HARDWARE UNITS OF EDPF-NT ................................................. 74
EDPF-NT Distributed Control System
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11.1 INDUSTRIAL NETWORK SWITCH .............................................................................................................. 74 11.2 EDPF-NT EXCLUSIVE POWER SUPPLY QUICK SWITCH DEVICE ............................................................. 75 11.3 EXCLUSIVE DC POWER SUPPLY ............................................................................................................. 77
CHAPTER XII EDPF-NT TYPE DEH SYSTEM ........................................................................................... 78
12.1 DCS-INTEGRATED DEH ........................................................................................................................ 78 12.2 TECHNICAL REQUIREMENTS OF EDPF-DEH CONTROL SYSTEM .......................................................... 78 12.3 EDPF-NT SYSTEM SPEED MEASUREMENT CARD .................................................................................. 79 12.4 ABOUT EDPF-NT SYSTEM VALVE CONTROL CARD ............................................................................... 80 12.5 1000 MW ULTRA-SUPER-CRITICAL STEAM-TURBINE ELECTROHYRAULIC CONTROL SYSTEM .............. 80
CHAPTER XIII DCS MONITORING SOFTWARE BASED ON WEB TECHNOLOGY ......................... 81
CHAPTER XIV EDPF-CP INDUSTRIAL AUTOMATION SYSTEM ......................................................... 83
CHAPTER XV TYPICAL ACHIEVEMENTS OF EDPF-NT ........................................................................ 85
15.1 2×1000MW ULTRA-SUPER-CRITICAL UNITS OF GUODIAN JIANBI POWER STATION ............................ 86 15.2 2×1000MW ULTRA-SUPER-CRITICAL UNITS OF GUOHUA XUZHOU POWER STATION .......................... 86 15.3 2×1000MW ULTRA-SUPER-CRITICAL UNITS OF GUODIAN HANCHUAN POWER STATION .................... 86 15.4 2×1000MW ULTRA-SUPER-CRITICAL SECONDARY REHEAT UNITS OF GUODIAN TAIZHOU POWER
STATION .......................................................................................................................................................... 87 15.5 600 MW SUPER-CRITICAL CYCLE FLUIDIZED-BED GENERATING UNITS OF SICHUAN BAIMA POWER
STATION .......................................................................................................................................................... 87 15.6 2×660MW ULTRA-SUPER-CRITICAL UNITS OF GUODIAN BULIAN POWER STATION ............................. 88
EDPF-NT Distributed Control System
1
Chapter I Outline of EDPF-NT Distributed Control System
EDPF-NT is an industrial automation product incorporating computer, network, database and
automatic control technology to realize integrated design of automatic control and information
management. It is featured as open structure, favorable hardware compatibility and software
extendibility. It is extensively used in the process automatic control and information monitoring
and management in industries like heat-engine station, nuclear power, hydropower station, new
energy, metallurgy, petroleum, chemicals, paper-making, concrete and sewage treatment.
EDPF-NT is applicable to various large and complicated industrial process control, and can frame
simple system to satisfy requirements of small-scale and low cost application. EDPF-NT is an
advanced process control system facing the whole production process.
1.1. Development history of EDPF-NT
Beijing GuoDianZhishen Control Technology Co., Ltd. started to develop EDPF series of DCS
with completely independent intellectual property since 1980s.
Based on borrowing ideas from product technology and concept of foreign automation control
systems, the Company developed the first dispersing microcomputer monitoring system
EDPF-1000 in China in 1988, and received the third prize of state scientific and technological
progress. Through a couple of years of efforts, the Company developed the first DCS product
EDPF-2000 with completely automatic intellectual property in China successfully in 1992.
Thereafter, the Company also released EDPF-3000 DCS using UNIX operating system platform
with good openness. In 1990s, EDPF series of DCS were widely used in automation
improvement projects of 200 MW thermal power units, and stood up to double examination of
plenty industrial practical applications and production running for a long time.
The latest automatic system product of EDPF family -- EDPF-NT was released in 1998, and
found wide use in industrial automation field immediately. A new generation of EDPF-NT, which
had incorporated the latest achievement of science and technology, was applied to the largest
thermal generating unit in China in 2006, which marked the performance of automatic control
system product of China stepping on a new stage, and had major practical significance on
improving the automation level of large size industrial enterprises in China.
EDPF-NT is a set of large-scale automation control system of international advanced level
developed against the requirements of large-scale complicate industrial processes. EDPF-NT has
integrated the merits of system EDPF-1000/EDPF-2000/EDPF-3000, adopted flexible domain
partition technology and architectural structure of distributed database without server, and
included developing Project Organizer and workstation software cross operation systems and
platforms to provide super performance capability under harsh environments, support seamless
connection of various field-bus equipment, and enable the function, performance and reliability
ranking among internationally advanced level.
Beijing GuoDianZhishen Control Technology Co., Ltd. executes the support project of the
National Development and Reform Commission on localization of manufacturing key technical
equipment of industrialization, adopts the latest achievements in fields of computer science,
network service technology and automatic control, and conducts plenty upgrading and developing
of EDPF-NT with independent intellectual property, so as to satisfy higher technical requirements
EDPF-NT Distributed Control System
2
of large industrial processes on control system. Introduction of new technologies has made it
more suitable to be used as station-level automation control system platform of higher monitoring
mode integrating enterprise management and control. Its characteristics are improved day by day
with stronger functions. The overall performance of EDPF-NT has ranked internationally leading
position, including some technical criteria exceeding current similar DCS technical features at
home and abroad. EDPF-NT has found wide use in various industries and fields like thermal
power, hydropower, metallurgy and chemicals. By the end of 2011, merely the capacity of
generators concerning EDPF-NT in commission in power sector has exceeded 61000 MW in
accumulation, including 6 units of 1000 MW ultra-super-critical generators, that are the largest in
China, 1 unit of 600 MW super-critical cycle fluidized-bed generator, which is the largest in the
world, 4 ×165MW large-scale hydropower stations and more than 40 units of 600 MW generators.
As the earliest domestic distributed control system running on 600 MW super-critical units in
China, realizing industrialization successfully, the earliest system applied on 1000 MW
ultra-super-critical unit and completing batch application, EDPF-NT has been developed into the
main force of China in high-end automation field breaking up foreign monopolization, and
currently the sole distributed control system product in China able to compete with foreign
well-known enterprises in automation control system tendering of ultra-large generator and
achieve success, and established the image of high-end brand of domestic automation system
successfully.
1.2 Primary standards and codes of system
EMC standards:
GB/T 17799.2-2003 (IEC61000-6-2) Electromagnetic Compatibility--Immunity Test in
Universal Standard Industrial Environment
GB/T17626. x-2006 (IEC61000-4-x: 2002) Electro Magnetic Compatibility of Industrial
Process Measurement and Control Equipment: Testing and Measuring Technology
Environment test and anti-corrosion standard:
GB/T 2421 - 1999 Basic Environmental Testing Procedures of Electric and Electronic
Products, Part 1: General (idt IEC 68-1: 1998)
GB/T 2424.2 - 2008 Basic Environmental Testing Procedures of Electric and Electronic
Products: Guide Rules for Damp Heat Test
GB/T 2423. x - 2008 (idt IEC 60068-2-x) Basic Environmental Testing Procedures of
Electric and Electronic Products
GB/T 17214.1 - 2005 Industrial Process Measurement and Control Devices, Operating
Conditions, Part 1: Climatic Conditions (idt IEC 60654-1: 1993)
GB/T 17214.4-2005 (IEC 60654-4: 1987) Operating Conditions of Industrial Process
Measurement and Control Devices, Part 4: Corrosion and Erosion Effects
ANSI/ISA-S71.04-1985 Environmental Conditions of Process Measurement and Control
System: Air Pollution
Electrical safety standard:
GB4943 — 2002 (IEC60950) National Safety Standard of Information Technology Equipment
IEC 61010-1/GB4793.1 Safety Requirements on Electric Equipment for measurement,
control and Laboratory, Part 1: General Requirements
EDPF-NT Distributed Control System
3
PLC standard:
GB/T15969. x (IEC 61131. x) Programmable Controller
Testing and acceptance codes:
GB/T 18272-2006 (IEC61069) Assessment of System Characteristics in Industrial Process
Measurement and Control System Evaluation
GB/T 18271.1 - 2000 Evaluation Method and Program of General Performance of Process
Measurement and Control Devices, Part 1: General (idt IEC 61298: 1995)
GB/T 18271.2 - 2000 Evaluation Method and Program of General Performance of Process
Measurement and Control Devices, Part 2: Test under Reference Conditions (idt IEC
61298-2: 1995)
GB/T18271.3 - 2000 Evaluation Method and Program of General Performance of Process
Measurement and Control Devices, Part 3: Test on Effects of Influence Quantity (idt IEC
61298-3: 1995)
GB/T 18271.4 - 2000 Evaluation Method and Program of General Performance of Process
Measurement and Control Devices, Part 4: Content of Assessment Report (idt IEC 61298-4:
1995)
DL/T 655-2006 Acceptance Test Rules on Safety Monitoring System of Boiler Furnace of
Thermal Power Station
DL/T 656-2006 On-line Acceptance Test Rules on Turbine Control System of Thermal Power
Station
DL/T 657-2006 Acceptance Test Rules on Analog Control System of Thermal Power Station
DL/T 658-2006 Acceptance Test Rules on Sequential Control of Thermal Power Station
DL/T 659-2006 Acceptance Test Rules on Distributed Control System of Thermal Power
Station
Other design standards:
DL/T1083-2008 Technical Specifications of Distributed Control System of Thermal Power
Station
DL/T 5175-2003 Technical Regulation on Thermal Control System Design of Thermal Power
Station
JB/T 6810-2014 Reliability Design Codes on Functional Template Module of Dispersing
Control System
GB/T 4208-2008 Case Protection Level (IP code)
JB/T 9270 - 1999 Inspection and Test Method of Process Input/Output Channels of
Industrial Control Microcomputer System
1.3 Main technical features of EDPF-NT
Advanced network topology
EDPF-NT data highway adopts high-speed industrial Ethernet protocol and peer network
structure without web server. It will never yield network bottle neck or hazard concentration, but
realizes dispersion of functions and risk.
Application to station level
The multiple domain network structure based on distributed real-time database and distributed
EDPF-NT Distributed Control System
4
computing environment adopts flexible domain partition technology to manage complex process
in domains as per process or function, which has solved the puzzles of high-performance
insulated interconnection and centralized monitoring of multiple control systems successfully,
provided technical base for large scale integration and running of automation control system, of
which the size of the systems may reach 1200,000 points, and satisfied process control demand
of various industries in deed.
Thorough redundant configuration
Key components of system like EDPF-NT data highway, process control station controller, power
supply, I/O module, I/O channel and interactive workstation can support redundant configuration.
The switching time of primary/standby controllers with warm standby mutually is less than 10 ms.
Network reduncancy of parallel dual-network has avoided the abuses of network switching,
improved instantaneity, reliability and fault-tolerant capability of system. Capability of redundant
configuration of I/O channels has significantly satisfied the application requirement on high
reliability.
Fault safety design of control system process
Fault safety of control system process is a key guideline in application design of EDPF-NT. Fault
safety is highlighted in aspects like configurations of control system, design of control logic,
realization of emergency trip function and countermeasures to extreme cases, so as to prevent
resist-operation of equipment, and improve safety level of control system effectively in case of not
increasing costs of control system.
New distributed real-time database
It has realized multi-domain distributed real-time database without server. It manages large data
volume of large scale system in partitions, which can reduce information complication and
network load, facilitate separate configuration and easier centralization of management. It has
realized multicasting real-time data within and among domains and subscribing two data
refreshing modes, which can choose the renewal strategy of real-time database based on
configurations of real system and balance the node loads of sender and receiver. The total
capacity of real-time database is more than 1200,000 points.
The high-capacity distributed real-time database taking station as basic unit adopts database
engine kernel based on cluster indexing technique, which has solved the problem of mutual
interference arising in stepped commissioning of DCS project magnificently, improved dynamic
security of system, and broken through the bottleneck of real-time performance. Partial
modification of database has no effect on other parts of the database, thus it is unnecessary to
recompile or load entirely.
Cross-platform system software
The software of distributed process control station and man-machine interaction equipment of
EDPF-NT is compatible to Windows and Linux operation systems, so as to adapt to the
requirements of different application domains on software environment. In the meanwhile, it has
spread the system functions. For example, the virtual DPU program running on Windows platform
is completely consistent with the program function and characteristics of DPU controller running
on dedicated hardware platform (using hard real-time kernel of Linux operation system), which
has created favorable conditions for development of simulation software of control system.
LINUX operation system is featured as openness, safety, high efficiency, stability and limited virus
attack. Replacing Windows with LINUX can ensure complete automation of kernel software of
EDPF-NT Distributed Control System
5
control system, and enable EDPF-NT with excellent characteristics of safety and controllability.
Full free-form format SAMA graphic control configuration software
Convenient full graphic SAMA chart control configuration function, very visual, easy-to-learn and
ease-of-use, what-you-see-be-what-you-get. Design drawing, configuration commissioning
drawing and as-built drawings are identical, and convenient for maintenance.
Dynamic loading technology of algorithms library of process control station
The algorithms library of process control station separates from the principal part of DPU support
software, both available for independent upgrading, on-line adding or replacing algorithm
respectively. It is not only convenient for upgrading and maintenance of system, but also provides
flexible function of customization to users. It convenient to develop special algorithms library
aimed at different control objectives and process control fields. It supports user to compile
advanced control algorithm through providing EDPF-NT add-value development kits.
History data recording station of high performance
EDPF-NT history data recording station has superior performance and stable operation.It adopts
revolving door compression technique to collect and save the parameters in production process
and derived data, provides basic data platform for optimized enterprise management, and
responds multi-user parallel query at second level. When 100,000 points of history data are
collected, it is still able to respond multi-user parallel query quickly. A couple of years of
production data can be saved easily through "volume" management function and with the help of
external storage medium. In the meanwhile, the system supports configurations of double history
stations, so as to ensure one history station can save data normally in case of the other one in
fault status.
Sophisticated on-line self-diagnostics
EDPF-NT has complete background layered software and hardware in-depth self-diagnosis
function, which can diagnose network, station, I/O modules and I/O channels.
Strict and comprehensive safety protection technical measures
The active safety protection system of EDPF-NT includes real-time scanning monitoring, safety
reinforcement immunization, virus defense and network intrusion defense, which build up a
complete multi-layer in-depth protection system from boundary to kernel in methods of separate
treatment, active monitoring level by level and overall coordination to protect safety of control
system.
The core operating system of EDPF-NT adopts LINUX to improve the safety and controllability
level of system. The safety and controllability capability of system is improved further through
complete automation of hardware and communication ground-up encryption.
Exclusive small and exquisite modular DPU controller
The controller of process control station adopts the latest embedded industrial microprocessor
with lower power consumption, more reliable operation and simpler maintenance. The integrated
special communication processor has enhanced performance of I/O bus, and mitigated the load
of main processor.
Advanced clock synchronization technology of process control station
The controller of process control station has built-in signaling interface of GPS PPS synchronous
clock, and the controller keeps clock synchronization with I/O modules highly through clock circuit,
which enables the time synchronization among control stations reaching millisecond level and
ensures cross-station SOE precision less than 1 ms. SOE module can be installed in any process
EDPF-NT Distributed Control System
6
control station separately.
Highly intelligent I/O modules
Each I/O module is designed with a CPU processor, communication coprocessor and redundant
network bus interface. Plenty driver level output modules with advanced control function and
aimed at various industrial working environments have been designed and produce based on
intelligent I/O modules.
Hardware systems of high reliability
The Company has developed redundancy unnecessary to switch over system networks and quick
switching of controller at millisecond level, and realized redundant switching analog input/output
channel level for the first time in China.
Aiming at high security requirement of process control, EDPF-NT system has particularly
designed and developed I/O redundant function to support channel-level redundant switching of
I/O modules. As compared to module-level redundant switching of I/O modules, channel-level
redundant switching has significantly improved the fault-tolerant capability of module in case of
crossing channel fault, and the average failure-free time has improved 1.5 times in theory.
Intensified structure design
All I/O modules adopt metal case whole sealing structure with features of dust-proof,
moisture-proof, anti-corrosion, static-free and anti-electromagnetic interference. It can be
installed at industrial site directly.
Resisting adverse working environments
The circuit boards of I/O modules are applied with military three-protection paint with super
capability of moisture-proof, anti-acid mist and salt fog resistance. It is particularly suitable for self
improvement of enterprise.
Built-in channel electric isolation mounting
All I/O channels adopt optical isolation and power isolation technique to realize electric isolation
to external and among lines.
Super protection capability
I/O channels are designed with PTC strong current protection circuit. When strong current signal
is wired in by accident, the channel will cut out for protection automatically, and return to normal
after strong current signal removed.
Application of virtual controller
With the help of cross-platform software transportation technology, the virtual controller software
of EDPF-NT system has almost identical functions and characteristics with the real controller
software, which has realized high accuracy simulation of control system, can be used for exciting
simulation industrial systems like heavy-duty generator, and comprehensive simulation test on
control policy, and support further extension of application functions.
Favorable openness
Independent and innovative extension IO interfaces (EIO) have provided uniform and flexible
access platform for various fieldbus equipment. It supports various network communication
protocols and multiple fieldbus standards.
EDPF-NT Distributed Control System
7
1.4 Main performance index of EDPF-NT
Performance index of system
System supports 100 domains and 1200,000 points;
Average load rate of network is 3.08 %, while maximum load rate 3.19 %;
Maximum controller load rate 20.6 %;
Precise and stable execution cycle of controller, minimum 10 mS;
When controller cycle 250 mS, mean response time to operating command 236 mS,
longest response time 300 mS.
Data highway communication network
Communication rate of 100/1000 MB/second based on fast switching industrial
Ethernet;
Technology adjoining multicasting and publish-subscribe to reduce network load
effectively;
Flexible domain partition, isolation among domains controllable, supporting 100
domains ×250 stations;
No real-time data concentration server, no network transmission bottleneck, no risk
concentration point;
Network redundancy system of double receiving and sending, no switching;
Real-time monitoring of network abnormality.
Process control station DPU (distributed processing unit)
X86 low power processor, dominant frequency 500 MHz;
Controller redundant warm standby, switching time of primary/standby controllers
less than 10 mS;
256MB RAM, 256MB FLASH;
Real-time Linux operation system;
Capacity of tag point up to 65000 points/controller;
Supporting hot plugging and on-line downloading;
Supporting 5 scanning periods, 10 mS-60S adjustable;
Redundant I/O bus using HDLC protocol (high-level data link control), rate 2 Mb/S;
Hooking up to 64 I/O modules/stations;
Processing up to 2048 digital quantities or 1024 analog quantities.
Input/output level network
Form of input/output level network: extension input/output bus (EIO) based on
industrial Ethernet connects to various fieldbus through protocol converter:
IOBUS bus protocol converter: special I/O bus for EDPF-NT system, internet
protocol: HDLC & RS485, synchronous data transmission;
FROFIBUS (master station) protocol converter: FROFIBUS DP fieldbus interface;
FF protocol converter: FILEDBUS fieldbus interface;
MODBUS protocol converter: MODBUS RTU/ASCII fieldbus interface;
MODBUS/TCP protocol converter: industrial Ethernet equipment interface;
Transmission tunnel of fieldbus equipment: providing fieldbus equipment manager
and direct linking channel with bus instrument;
Input/output level network can have redundant configuration.
EDPF-NT Distributed Control System
8
Input/output modules
All I/O modules adopt double-circuit DC power supply;
Metal case whole sealing reinforced structure with features of dust-proof, static-free,
anti-electromagnetic interference, and maintenance-free in life-cycle.
Unique PTC electrical protection technology, measuring channel capable to 250
VAC/DC AC signal free of damage;
Signal isolation, power isolation and communication isolation in I/O channels, triple
isolation measures enabling system with powerful interference-free feature;
The surfaces of module circuit board and components are processed with special
paint with featured of mould-proof, moisture-proof and salt fog resistance;
Large signal precision 0.1 %, small signal precision 0.2 %;
Resistance to common mode voltage larger than 1000 V;
Common-mode rejection ratio larger than 90 db, differential mode rejection ratio
larger than 60 db;
Hot pluggable;
Local or remote I/O capability;
Terminal seats of module rail-mounted, built-in connector reducing power and
communication wiring,
Performance index of upper computer:
Image refresh rate 500 mS;
Supporting monitor display of multiple panels and multiple windows;
Supporting Windows and Linux operation systems and different application
demands in the meanwhile;
Integrating development environment-Project Organizer as per project
management;
Supporting standard full graphic control configuration of SAMA;
The virtual DPU running on upper computer is completely consistent with the
functions of real controller, which is convenient for simulation commissioning of
system and supports further function extension.
Performance index of history station
Using revolving door compression technique;
Responding multi-user parallel query at second level;
'Volume" management function, able to save history data permanently and provide
fast query;
Supporting redundant configurations of history station.
1.5 Severe quality assurance measure
1.5.1 Implementing ISO9001 quality management system thoroughly.
1.5.2 The production and inspection process of controller and I/O modules in hardware units
execute comparable standards of aerospace industry, of which the strictness and rigorousness
can ensure ultra high reliability of hardware units.
1.5.3 All hardware units are subject to rigorous high-temperature and power-on aging tests, which
fatigues the products with high-strength periodic cycles in specific environment test chamber -
EDPF-NT Distributed Control System
9
20 ℃~70 ℃, rejects products of earlier failure effectively, ensures ex-works acceptability and
long-term stable and reliable operation of hardware products, and guarantees the overall quality
level of equipment.
1.5.4 After multi-year practices of DCS applications, the Company has integrated plenty
application software module and optimization control software module through inspection of
practice. In project applications, plenty using of these basic modules can improve project speed
and ensure project quality.
1.5.5 Matured and sophisticated total system simulation program, strictly implementing ex-works
testing and acceptance procedure.
EDPF-NT Distributed Control System
10
Chapter II Structure and basic frame of EDPF-NT
2.1 Structure of EDPF-NT
EDPF-NT is a set of advanced process control system designed and developed incorporating the
progressive ideas of numerous similar international systems and conditions of China. EDPF-NT is
based on network communication system, takes "station" as primary element, which faces to
function and objective, and the distributed dynamic real-time database designed specially is used
for management of all data demanded for system operating dispersed over all stations.
As further improvement of requirements on enterprise benefits and effectiveness, enterprises are
no longer satisfied with automation level development of device or single system, instead of
taking the whole station as an organic body in operation, control and management. EDPF-NT is a
new automation control system platform developed after absorbing the latest achievements of
computer technology, network service technology and automatic control technology, exactly
satisfying the demand of large size industrial enterprise on whole station comprehensive
monitoring.
EDPF-NT supports multiple domain network environment based on distributed computing
environment (DCE) facing station level applications. It adopts flexible domain partition technology,
manages complicate production process in domains as per process or function, and has solved
the functional requirement of multiple control systems on isolation, interconnection and
centralized monitoring successfully.
EDPF-NT system can be a large-scale distributed control system integrating multiple "domains".
Each domain is a middle or small system, which completes relatively independent function of data
collection, processing and control. All domains are connected with each other through network to
develop a large-scale integrated automatic system. All domains are isolated with each other, and
information among domains can be isolated or exchanged selectively upon request, which can
reduce the size of information process of all functional subsystems, reduce and eliminate
coupling among different controlled devices and control systems, promote cellular structurization
of the whole control system, and improve system reliability.
EDPF-NT based on flexible domain partition technology supports the demand of massive
applications, requirements of complex process on high performance, highly openness and
integration capability of third-party equipment and higher monitoring mode requirement of
integrated management and control.
The stations of EDPF-NT system include two general categories: controller and (MMI)
man-machine interaction workstation.
The controller of EDPF-NT system can be the controller of real process control station, or a virtual
controller running on a general computer.
MMI workstations can be distinguished into engineer station, operator station, history data
recording station, computer station, report station and interface workstation as per functions. One
computer is permitted to install MMI workstation software of multi-functions in the meanwhile to
construct comprehensive MMI workstation.
A MMI workstation can add to multiple "domains" in the meanwhile, but a controller only belongs
to one "domain".
EDPF-NT Distributed Control System
11
The system composition as per the following chapters.
2.2 Layered multi-domain network communication system
2.2.1 Network communication system of EDPF-NT shall be distinguished into three layers:
Data highway MCN (Management and Control Net),
EIO (Extended Input/Output),
FIO (Field I/O).
The system packs technical details independent from the outside world at each level, which
enables information flow of different levels and types going their own ways, and reduces crossing
and coupling of information streams. The nodes at each layer only face the data demanded and
interested. Private or standard communication protocols are designed, realized or directly
adopted aiming at features of local layer specially, which is convenient to comply with universal
standard while ensuring information security and keeping self features, and realize open network
structure.
2.2.2 MCN layer is the upper layer management and control information network of EDPF-NT
system, and the bridge of MMI workstation and controller station realizing information exchange.
It adopts industrial switching Ethernet in any network topology like star type/loop type/tree
type/bus type. Dual-networks are parallel in redundancy. The network communication rate can be
100 Mbps or 1000 Mbps, and network refreshing capability within domain shall be 320,000
points/second.
MCN supports "distributed computing environment". It is based on TCP/IP protocol, and provides
network communication service for the total system. It adopts object-oriented approach design
and realization.
Physically, MCN can be multiple switching Ethernet linked through intelligent network switch. The
intelligent network connecting device among domains can provide further security isolation
among various sub-nets. Logically, all nodes on the entire network are organized into multiple
"domains" independent with each other. It supports up to 100 domains. Each domain holds up to
253 stations. The communication among all domains are mutually isolated and non-interfering.
MCN has no real-time data server logically and physically, instead of running on network of any
topology structure in flat or peer mode, without concentrated storage or forwarding of data or
extra data translation. The real-time data flow channel has no bottleneck, but each network node
uses band with sufficiently and evenly without outstanding hot spot. It has also avoided delay
triggered by data route forwarding. Particularly in case of accident, the network data flow will not
jump, data flow will not buildup at node of web server relevantly, or there is no worry of web server
in fault resulting in total system collapsed.
2.2.3 EIO is located at layer 2 of three-layer network structure, a information exchange mode
newly defined for external equipment like controller, controlled device, and third-party equipment.
EIO is upward compatible to controller and virtual controller, downward compatible to local I/O,
EIO or virtual card accessed through Ethernet, network I/O based on fieldbus protocol.
EIO network is compatible to industrial Ethernet protocol. The topology structure of network
can adopt tree or loop type.Network redundancy is supported.
EIO network segment is not limited to one controller, but two or more controllers can manage
and use the same EIO network segment in the meanwhile. Controllers can stack on the
same EIO network segment, thus it can realize extend and reallocating of control functions
EDPF-NT Distributed Control System
12
on the same EIO network segment. A couple of DPUs can share 1 EIO network, and
establish a super control unit (SPU), while a SPU can have a couple of EIO network
segments internally.
EIO has defined a set of uniform mode of information description, which can describe the
local I/O points, local cards, local algorithms, remote I/O points, remote algorithms, and
remote control strategies uniformly.
The control function can distribute realization and centralized administration among
controllers and EIO network access equipment.
EIO network provides transmission tunnel for configuration of site equipment and adjustment
information, and transparent transmission channel for real-time information and non-real time
information.
Integration of hetero-system. At EIO layer, it can integrate third-party systems like simulation
and PLC in the same way.
EIO supports network I/O based on EIO protocol, and other standard fieldbus devices accessed
through protocol converter. Through EIO, it can provide complete support to various fieldbus
equipment.
Introduction of EIO technology has overturned the organization of process control station of
conventional DCS, and the openness of system is extremely improved.
2.2.4 FIO protocol at field input/output layer is provided by I/O subsystem equipment at field layer
of access system. It supports various standard and private fieldbus transport protocols, e.g.
FROFIBUS DP, FIELDBUS, HART, MODBUS RTU and IOBUS of EDPF-NT.
2.3 Distributed process control station (DPU)
Distributed process control station (DPU) mainly completes data collection, processing and
control of production process of the controlled process objective. Process control station is mainly
composed of components including cabinet, redundant power, redundant controller, redundant
I/O bus, smart I/O subsystem, and fieldbus communication module at procedure level. Among
others, the redundant controller and I/O subsystem are linked with redundant high-speed I/O bus.
Controller and I/O subsystem permit distributed arrangement, and the performance is not
reduced in the range of 40 km in case of deploying special I/O bus fiber extension module.
Distributed process control station implements data acquisition and processing to field process
signal, and implements control calculation as per control policy of configuration, outputs
regulatory signal to operating mechanism realize process control over the controlled device.The
controller of process control station has built-in LINUX hard real-time operation system kernel,
system support software and control algorithm module library for real-time multitasks scheduling
as per priority modes.
Distributed process control station adopts warm standby redundancy to realize redundant
configuration of controller. Primary/standby controllers are equipped with 2-unit monitoring circuits
respectively. In normal operations, the master controller owns the control power of input/output
and station calculation, and transmits the performance data and process of its own to the backup
controller through 2-unit monitoring cards in real time. The backup controller receives information
from the master controller in real time and keeps synchronization with the master controller. The
backup controller monitors the working condition of the master controller through 2-unit
monitoring cards in real time. Once the master controller fails, the backup controller will grab the
EDPF-NT Distributed Control System
13
control power of input/output and station calculation undisturbedly and immediately, so as to
ensure absolute control of the process station over process objective. Primary/standby controllers
can complete control power switching in 10 ms completely undisturbedly. When primary/standby
controllers switch, the system will send alarm information through network and panel indication of
controller to inform system operator. The switching process will never cause the process
communication interrupted or data lost.
Each controller station can contain 65000 points.
2.4 Engineer station (ENG)
Engineer station is mainly used for system configuration and maintenance. A system domain can
have multiple engineer stations, or the complete set of multi-domain control system only uses one
engineer station. An engineer station is added to each DCS domain to be global engineer station,
so as to configure and maintain the decentralized control subsystems in multiple domains in the
meanwhile.
The complete system needs to assign a global engineer station as project server. A project
merely sets up an authorized project server, while the other engineer stations can be subject to
remote operation through network accessing project server and complete all tasks of
configuration. The project server is designed with interlock function to ensure uniqueness of data.
Engineer station is liable to plan system size, create project, complete domain and station
creation, and generate system database, monitoring operation panel, control algorithm, warning
function and report function. In the meanwhile, it has functions like downloading and uploading
control applications of process control station.
Engineer station is installed with functional software including Project Organizer, project server,
security policy creator, projecting configuration and management software kit, point record bulk
operation tool, DropTool, virtual controller and time synchronization tool.
2.5 Operator station (OPR)
EDPF-NT OPR is a main man-machine interaction equipment provided by the control system. It
has provided a powerful operating environment for operators. An operator realizes computerized
monitoring operations of the controlled technological equipment with keyboard and mouse
through the multiple windows of operating station, including graphic flow diagram, trend panel,
parameter list display, process alarm display, history trend panel and control adjustment.
Standard operator station is equipped with completely identical software and hardware system for
backup of each other.
Operator station can be added to multiple control domains in the meanwhile to have global
characteristics, and can monitor and operate the controlled technological equipment on multiple
domains in the meanwhile.
Operator station provides the following primary functions:
Display operating function
Alarm display and processing function
Control operation function
History event query function
Operation record query function
EDPF-NT Distributed Control System
14
Operation instruction function
2.6 History data recording station (HSR)
HSR adopts exception report and binary compressed format to collect and save the system data
in real time, including catching and recording of events like alarm, log, SOE, accident recollection
and operations, and history trend collection of modulating parameters and secondary parameters.
HSR can respond multi-user parallel query. History data can be saved for permanently through
"volume" management function and with the help of external storage medium for fast query.
2.7 Report station (LOG)
Complete regular reporting like shift report, daily report, monthly record and small target
competition, collection and organization of incident remembrance report, reporting caused by
time or event and reporting requested from time to time. These reports can be printed promptly
and timely, or as requested by operator. The report head and format can be defined via
configuration of engineer station.
2.8 Performance computer station (CAC)
CAC mainly provides two functions: programming and operating environment for large special
computation software; and developing and running platform of special software for customer
engineer. Performance computer station provides programming interface of DCS real-time
database and software development kit. Skilled customer engineer can compile dedicated control
and computation software, enable seamless connection with DCS, and add function of control
system as per self requirements.
2.9 Multi-function interface workstation (GATEWAY)
Large-scale data two-way communication interface connected to third-party computer system.
Supporting various international standards and communication protocols. For the purpose to
ensure security of data transmission, GATEWAY can be equipped with software and hardware
network firewall or one-way isolation gateway.
All functional stations of the aforesaid EDPF-NT have been designed with distributed real-time
database interface. The number of various functional stations can be configured flexibly based on
system size. Application of massive distributed control system can use hundreds of workstations,
and important functional stations can have redundant configuration.In small occasions of
application, the function of multiple workstations can be combined to a single station for
realization.
EDPF-NT Distributed Control System
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Chapter III Network information technology and safety
management and control platform of massive whole station
integrated control system
3.1 Network information technology of massive whole station integrated
system
Massive whole station integrated control system realizes management and control mode with
whole station centralized monitoring and graded monitoring combined, requires interconnection
and intercommunication of control systems of each independent production technology, and
network communications control under large information stream. Therefore, the target of network
message technology of massive whole station integrated control system shall be meeting the
requirements of network communication system on large handling capacity, high efficiency, no
bottleneck, good system expandability and super reliability.
EDPF-NT system has realized the massive whole station integrated control system through three
techniques as follows:
Flat network structure
flexible domain partition technology
Communication technology with multicasting and publish-subscribe combined
3.1.1 Flat network structure
The traditional DCS network communication system can be distinguished into process control
layer and system information layer. DCS adopts computer network to link all distributed process
control stations and frame process control layer, and link all MMI workstations to frame system
information layer. Two layers of network are linked through gateway. Because the DCS distributed
process control station of this structure is usually designed as slave station, the inter-layer
gateway shall have the function of I/O server of control layer equipment in polling procedure at
the same time, thus it is referred to as web server. The information layer of DCS system equipped
with network server adopts C/S structure, and all "stations" are slave stations of network server.
Web server is the bottleneck and hazard concentration point of the total system, and its running
status has decided the stability and reliability of whole DCS system directly. The MMI workstation
with distributed control system of this C/S structure may not access each process control station
directly, instead of all commands even data exchange among control stations to be
stored-and-forwarded via network servers, which results in large transmission delay and
response lag of system on control command. For C/S structure, when DCS runs normally, the
network load is low.However, when the controlled devices run abnormally, the network flow will
jump, which is similar to avalanche effect. Because all data of system shall be transmitted through
web server, it tends to cause serious network congestion near the network interface, and some
DCS control stations or the total system will face dangerous situation out of control, or even result
in overall collapse of the control system. This shows that the DCS design scheme of C/S structure
goes against the working principle of distributed control system: "dispersion of function,
dispersion of risk, information concentration". Facts has proved that web server is the chief culprit
resulting in system hazard concentrated.
EDPF-NT Distributed Control System
16
Particular DCS manufacturer compacts the process control layer and system information layer
network for the purpose to evade the accuse on network database server, and enables certain
operator stations with the functions of network database server concurrently. This DCS of invisible
web server structure has not changed the C/S structure problem at all, the default is still there, but
the load of other MMI workstations are heavier, and the operating condition worsens, which shall
be worried.
EDPF-NT has combined the process control layer and system information layer network
(flattened network). All DCS devices are even network nodes of data highway. The system adopts
multicasting and point-to-point unicasting communication means without web server, thus there is
no problem of hazard or function concentrated or network bottleneck. All operating commands
sent by MMI workstation will be sent to process control station directly. Any fault will be limited to
the limited range, instead of resulting in system crash, and it has realized dispersion of function
and dispersion of risk in deed.
3.1.2 flexible domain partition technology
Modern intelligent large size industrial enterprise urge for configuration of automation control
system taking the whole station process primary and additional equipment or production process
station as one piece increasingly. Whole station primary additional equipment at all levels or
control subsystems of production shop shall be interconnected via computer network. There
cannot have any form of illegal data coupling among control subsystems, however, they shall
establish bidirectional flow channel of legal information, shape a body, and address the special
tasks of station-level control system jointly. The system shall also need to design global operation
and monitoring devices to monitor any controlled process equipment in the whole station in the
meanwhile.
Currently, the prevailing global distributed control systems have constantly "climate sickness" in
this new demand on control function. The traditional DCS network communication system is
designed based on one network segment linked to all "station"devices. Multiple DCS shall be
interconnected via gateway devices (gateway, bridge, network router or web server). Gateway
configured in system will reduce the overall performance of control system and reliability.
For the purpose to overcome the aforesaid default, in recent years, some foreign systems use
three-layer switching route function of network switch to realize network interconnect of control
system. It has been proved in practice that although this program has good reliability, but the
network load is high, delay of data forwarding is large, and operational efficiency of total system is
reduced.
For the purpose to solve the functional requirement facing station level applications, EDPF-NT
adopts advanced network management technique --ACL access control list and IGMP
multicasting, to develop flexible multiple domain network management function, and has solved
the functional requirement on isolated interconnection and centralized monitoring of distributed
control system successfully. It has satisfied the process control demand of whole station level
enterprise automation control system truly.
The primary function of ACL technique is intended to realize recognition function of data flow.
Network device can filter data package through configurations of a series of matching rules and
recognize the message in need to be filtered. After specific message recognized, the relevant
data packages are forwarded or rejected based on pre-set strategies. Therefore, after relevant
suitable ACL configured by intelligent network switch, DCS subsystems of different domains are
EDPF-NT Distributed Control System
17
impossible to be connected directly, thus it has realized complete isolation among DCS domains,
and ensured exact arrival of correct cross-domain data transmission packets.
Thus, it is not necessary to configure specific domain isolation device, which has not only ensured
high-speed passing of data, but also relieved of common and special gateway, which is the
communication equipment with severely adverse effect on DCS performance and reliability,
decreased device category and quantity, simplified system structure, and reduced risk.
Currently, a lot of advanced industrial network switches with two-layer exchange function can
support ACL and IGMP techniques. This technology can realize interconnection of multiple
control systems, provide features of high reliability, fast running speed, and low network load, and
improve the performance of overall control system greatly.
The system adopts flexible domain partition technology to manage complex process in domains
as per process or function. Each domain is relatively independent, and information among
domains can be isolated or exchanged selectively upon request, which can reduce the
processing size of all functional subsystems, reduce or eliminate coupling among different
controlled devices and control systems, and promote cellular structurization of the whole control
system. Automatic complete control system based on flexible domain partition technology
supports the demand of massive applications, requirements of complex process on high
performance, highly openness and integration capability of third-party equipment and higher
monitoring mode requirement of integrated management and control.
The whole station level EDPF-NT using this technology is composed of multiple decentralized
control subsystems working in different network domains. The control system in each domain has
independent DCS full kernel structure, which is corresponding to a set of relatively independent
process controlled device or station respectively. They are linked into a body via data highway.
The control systems in all domains are mutually insulated and running independently. In the
meanwhile, the valid and effective data can flow in two-way among control systems of all
domains.Various MMI workstations can become the within-domain or global devices manage and
operate the decentralized control subsystems and the controlled devices in these domains after
adding to single domain or multiple domains.
Engineer station is designed and installed with "Project Organizer" aiming at multi-domain
application environment, which has integrated the kernel task of control systems engineering
under single application platform. With support of Project Organizer, it is possible to operate the
whole control system including network planning, network domain defining, domain creation,
station creation, point creation, database creation, uploading and downloading. It is possible to
call up the external tools directly like editor of control policy and editor of process image, as well
as software tools with convenient support to control system in life time. Various decentralized
control subsystems can be configured, commissioned and operated independently, then linked to
uniform station-level network in batch and series for uniform monitoring, centralized operation and
maintenance.
The station level automation control system solution of EDPF-NT has simple and distinct network
structure, compact and reliable configuration mode and control function, which has directly
mitigated the working load of running and maintenance staff. It has great technical superiority as
compared to other DCS solutions.
For the purpose to test the capacity of EDPF-NT undertaking whole station integrated control
system, large-scale power station equipped with 6 units of 1000 MW thermal generators is taken
EDPF-NT Distributed Control System
18
as test object. The 6 ×1000MW unit whole station primary and additional equipment integrated
control system model has been designed based on the real data of 1000 MW units before
implementing strict pressure simulation test of network communication system. In case of of
network domains up to 25, and data quantity up to 1200,000 points, through field measurement of
11 key observation points, various operating indexes of EDPF-NT network communication system
have satisfied the technical specifications of the power planning institute.
3.1.3 Communication technology with multicasting and publish-subscribe combined
It realizes information within domain multicasted as required and information of each domain
separated as per exchange port, and reduced the network data switching load and node message
routing and receiving load.
Receiving and processing of excess port data in routine control system network communication
will worsen the working environment of controller, and then effect the reliability of control system.
EDPF-NT system adopts release/subscribe and multicasting technology, in which the releasing
station only broadcasts the data demanded (subscribed) by other devices, and the data not
subscribed by any device will not appear on network, which has reduced broadcasting data
volume effectively. Multicasting technology has shielded the DPU controller from receiving
broadcasting data packet outside the domain, and reduced the communication receiving and
processing load of DPU controller greatly. And it has improved the overall reliability of massive
control system.
3.2 Safety management and control platform
After power station has realized the management and control integration with DCS as kernel, all
key infrastructures rely on DCS highly, any rule-breaking operation, virus damage, network attack
or intrusion aiming at control system may result in consequences in the lap of the gods. Therefore,
in construction of digitized power station, there is no time to delay in reinforcement of information
safety management of integrated DCS.
Beijing GuoDianZhishen Control Technology Co., Ltd. undertook a key project in the advanced
manufacturing technique field of 863 Program in 2007 —— "complete automatic control system
of key projects in thermal power industry". This project has carried on study in aspect of DCS
information security. The Company has proposed "DCS system active safety protection plan" in
2010, and developed the first generation of DCS network safety management and control
platform --NETMON.
Beijing GuoDianZhishen Control Technology Co., Ltd. collaborated with China Standard Software
Co., Ltd. in 2011 for product optimization, adopted NeoKylin safe operation system to improve the
safety protection level of DCS host, and constructed the second generation of DCS network
safety management and control platform — NETMON II.
NETMON II adopts the security control technology and method with active network information
detection and network node equipment safety reinforcement combined, builds up a complete
multi-layer network security system through active monitoring level by level and overall
coordination, provides safe and reliable network operation environment for digitized power station
platform, and ensures business continuity and data security.
The implementation layer of NETMON II reinforces security of overall network devices and the
host, and implements the security policy of DCS security management and control platform, in
four aspects:
EDPF-NT Distributed Control System
19
Safety protection of DCS host operating system
It adopts operation system compatible with requirements of Class IV of Chinese standard
GB/T20272 and GB17859, constructs trusted computing base (TCB), and establishes dynamic
and complete security system, and the security policies from kernel to application layer have
realized functions like status identification, compulsory access control, security auditing, white list
control, management of mobile storage medium, data protection and anti-virus.
Safety protection of network boundary
After integrating and configuring devices like IPS, firewall, single (double)-way insulated gateway,
it has realized management and control of communication between DCS network and
surroundings, so as to stop external network intrusion.
Internal safety protection of DCS network
Periodic scanning of system devices (HMI, DPU, network switch, etc.) and topology structure at
network link layer can realize functions like devices and network state monitoring, broadcast
storm suppression, and identification of illegal network access, and generate alarm automatically.
inter-domain security isolation
Configuration of network isolation technique can filter network flow and communication protocol
and realize inter-domain data isolation.
IDS intrusion inspection can realize monitoring of network running status, and do the best to find
various attack attempts, attack behaviors or attack results, so as to ensure the confidentiality,
completeness and availability of network system resources.
Functional
item Substance
Configuration
and
management
function
Support concentrated configuration and management of equipment
Support backup and recovery of configuration file
DCS
System safety compatible with requirements of Class IV of Chinese standard GB/T20272 and
GB17859
Realize terminal application control based on white list
Realize tracking, analyzing and warning functions of system safety event
Industrial control over collection of network flow and identification of real-time industrial
control protocol and contents
Network
Define DCS network topology, and describe physical linkage among devices
Monitor the running status of various node equipment on DCS network in real time
Audit DCS network topology in real time, alarm connection error, and block all illegal network
connection
Support uniform collection and browsing of equipment alarms of the whole network
Support multiple alarming modes, panel blinks, and alarm sounds
Support customization of performance threshold of monitoring performance index
Monitor entry history of data and equipment alarm information for later query
EDPF-NT Distributed Control System
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Chapter IV Monitoring and operating software of
EDPF-NT
Operator station is a key component of EDPF-NT, and a type of MMI station (Man Machine
Interface).
Under real-time running status, an operator can realize real-time monitoring of production process
through operator station.A system may have multiple operator stations, which are mutually
independent, non-interfering, and backup of each other.
Operator stations can provide real-time data of production process for operators in process image,
curve and table, and operators can carry on real-time intervention on production process with the
help of MMI function.
The interactive workstation of EDPF-NT adopts Windows XP/Linux Chinese windows as
operation system platform. Operator station provides abundant monitoring panels of high
resolution and operating performance with prompt response featured as practicality, aesthetic
appearance, easy-to-learn and ease-of-use, particularly suitable for the monitoring and operating
customs of omnipotent operators in China. Operations of panel calling and monitoring control are
realized through flexible mouse or keyboard.
The software of operator station can be distinguished into MMI software and supporting service
software.
The primary function of MMI software is to provide rich information and MMI methods for users. It
accepts operation of user. These software can run or be closed as required from time to time.
The function of supporting service software provides service and support platform for MMI
software, e.g. data collection, communication management, file transfer, while these software
shall be always running.
Some programs like DCS Commander serve as MMI program as well as command outlet of other
programs, thus it shall also be when programs locked to it run.
The following table provides software list of operator station
Program Function Starting Category
DropStarter Station Bootmgr Automatic or desktop
shortcut MMI
AppBar Application toolbar DropStarter MMI
dceM DCS communication
environment DropStarter Service
dFTs File transfer DropStarter Service
tc Collecting real-time
trend DropStarter Service
DCS Commander DCS command center DropStarter MMI
GD Graphics Display AppBar MMI
PntBrowser Point record browser AppBar MMI
AlgDisplay Algorithm browser AppBar MMI
EDPF-NT Distributed Control System
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hsrt History trend display AppBar MMI
td Real-time trend
display AppBar MMI
MsgBrowser Report window AppBar MMI
4.1 Multi-window display mode
Operator station adopts multi-thread technology to support the operating and monitoring
functions of multiple display of multi-window panels. It can open multiple overlapping or
layering windows, while each window is active in real time. It provide panel open window
display, rolling panel display and zooming display of device service conditions, so that the
operators can monitor thoroughly, recognize quickly, and implement correct operations. A
user can use the panel creator provided by system to customize monitoring and operating
panels of own style.
System provides multiple modes of panel calling for convenience of users.Major calling
modes include:
Call up with shortcut key
Call up from directory panel
Click on panel linkage to call up
Call up panel as per before and after pages
Call up with geographic map
Key in panel name to call up
The upper part of display panel is designed with application toolbar AppBar, which provides
the start buttons of various applications for operator.Click these buttons to start relevant
applications.
Fig. 4-1 Tiled display of multiple windows Fig. 4-2 Application toolbar
The display panel supports function of graphic computation, and can configure computation
and conditional statements. Under running status, these statements are executed in real time,
have effects on the results of graphic display, including to change graphical color, alphabetic
character, icon, hide graphics, switch foreground/background, blinking.
The display panel can define various operating zones. An operator can realize various
scheduled operation through operating zone on image,e.g. calling floating menu, opening
another home page, opening a window panel (operating panel or demodulator panel),
EDPF-NT Distributed Control System
22
opening algorithm browser, opening point browser, opening trend window, sending control
command, etc.
Coupling with advanced graphic configurator, a user can design multiple control algorithm
operating zones on the simulated diagram. Click these control zones with mouse, and the
operating panels of assigned devices popping up in windows or switching to control system
panel, so as to complete various control functions and parameter setting with great simplicity
and convenience.
The system provides plenty standard operating panels programmed with 3D graphic
techniques. The definition and using of these operating panels are very simple. A user
merely need to fill in the relevant attribute and parameter names as required. There are
multiple types of operating panels to satisfy requirements of various algorithms and operating
mechanisms. Standard operating panels can be blended with other graphic icons in using to
satisfy special requirement of user. A user can customize special operating panels.
Fig. 4-3 Popping-up operating panel Fig. 4-4 Example of window panel
Fig. 4-5 Example of floating menu
The following table has included some examples of basic control commands
No. Command Function Continuous
execution 1 O_Goto_Manual Switch to manual
2 O_Goto_Auto Switch to auto
3 O_Setting_Inc Setting value
increasing slowly
Yes
4 O_Setting_Dec Setting value
decreasing slowly
Yes
5 O_Setting_IncFast Setting value
increasing quickly
Yes
EDPF-NT Distributed Control System
23
6 O_Setting_DecFast Setting value
decreasing quickly
Yes
7 O_Setting_Value Directly set up as
constant
8 O_Setting_IncDec Directly
increase/decrease
setting value
9 O_Output_Inc Output slow
increasing
Yes
10 O_Output_Dec Output slow
decreasing
Yes
11 O_Output_IncFast Output fast increasing Yes
12 O_Output_DecFast Output fast decreasing Yes
13 O_Output_Value Direct exporting
14 O_Output_IncDec Directly
increase/decrease
output value
15 O_P1~O_P16 PK command
4.2 Trend display and group display
Real-time trend display is an important function of real-time data display of EDPF-NT OPR.
Real-time trend display means to display the real-time data of measuring point with curve in a
period of time with spacing from 5 minutes to 1 hour.
All modulating data can be used for trend display. Trend display panels can be distinguished
into temporarily trend panel and fixed trend panel. Temporarily trend panel is used for
operator to form trend panel as required from time to time, and fixed trend panel is the
grouped trend panel pre-set. In addition, a user can also arrange trend display at will in the
panels called out currently.
Each trend display panels can display up to 4 trend windows in the meanwhile, and real-time
curves up to 8 measuring points. A user can customize the window number, curve color and
curve to be displayed in which window.
The definition of grouped trend panels is very simple and convenient, and a user can
organize the grouped trend display as per own requirements. Click operating button to set up
trend display panels, including configuration of data, time, list, trend attributes, coordinate
axis and point color.
A user can open any number of history and real-time data curve windows, just click the left
button on panel, drag parameters to the target window, and query the history and real-time
curves easily.
Fig. 4-6 Display panel of real-time trend 4-7 Display panel of drag parameters to real-time trend
panel 4-8 Display panel of defining grouped trend
EDPF-NT Distributed Control System
24
4.3 Processing alarm information
Alarm information reflects abnormal situation of production processes of the controlled device,
and is an important method of operator to learn about production processes. The alarm
management function of EDPF-NT can process multiple types and grades of alarm information
including parameter range over-limit, sensor parameter over-limit, and switching value jumping.
Alarm of parameters can be distinguished into multiple priorities, so as to reflect the significance
level of parameter alarm.
Alarm information is displayed in forms of light-word alarm and report window.
4.3.1 Light-word alarm
When significant alarm event occurs, the alarm information is shown on the current screen in
light-word form. The light-word alarm program advises alarm information with tex and sound to
attract attention of operating personnel.Alarm can be distinguished into two classes as per
severity with different alarm colors configured respectively. The running interface of light-word
alarm shall be shown in figure, including all partitions and groups. Each item in the table indicates
a group. When any alarm at any point occurs, the color of alarm light will blinks unceasingly. If
audible alarm has been configured, the loudspeaker will make a predefined sound.After the alarm
confirmed, the alarm light will not blink, but glows continually till the point value concerning this
alarm restored to normal range.If the alarm is not confirmed, but alarm has been eliminated,
alarm light still blinks, but color is changed.Such alarm will return to normal color after
confirmation.
Fig. 4-9 Panel of light-word alarm group Fig. 4-10 Panel of light-word alarm
The system is designed with function of alarm confirmation, so as to mark if the operator has
learned about parameter alarm or alarm canceling status. The confirmed alarm information will be
discriminated color different color on alarm panel.
The system has screening function of alarm information. For example, it is possible to screen
alarm information as per alarm level or type, and the alarm information only satisfying the
boundaries will be shown on alarm monitoring panel.
The function of sound alarm provided by the system can assign different alarm sound frequency
for different alarm groups or priorities. It can also play specific "wav" voice file for different alarm
information.
4.3.2 Report window
The report window function (MSGBrowser) is used to carry on real-time monitoring at operator
EDPF-NT Distributed Control System
25
station and view information in system operation, including alarm, event and user operations. The
report window panel has provided detailed and complete alarm information for operators.
This report window refreshes alarm information in roll mode. The latest alarm event received is
displayed undemost of table, and each line displays an alarm event.
Click on application toolbar AppBar to start alarm monitoring program.
If the operator station receives new alarm information, the icon on AppBar will turn into .
The report window panel can not only provide alarm information reflecting the running status of
the monitored object, but also display important event information reflecting the running and
operational details of system, e.g.: initial start of station, switching auto/manual status of control
circuit, important operations (parameter modification, etc.). Event information can be displayed,
printed on operator station and saved on HSR. This function has vital role for analyzing accident
cause.
The report window provides the function of retrieving information with key words, so that an
operator can locate the alarm event information in multitudinous event information exactly.
An operator can choose "auto roll", "stop auto roll" or " clear up list" to change report window
display.
Fig. 4-11 Alarm information displayed in clipping window Fig. 4-12 Alarm retrieval function
of clipping window
4.4 PntBrowser
PntBrowser of EDPF-NT operator station provides abundant functions of detailed system
measuring point record display. All information of all parameters on panel including the current
value, alarm, hardware-address and quality can be received easily just clicking right button of
mouse.
EDPF-NT Distributed Control System
26
Fig. 4-13 Open point record andbrowse panel
4.4.1 Information of point record
Information of point record includes real-time running information and measuring point
configuration information. The configuration information is only for browsing instead of alteration
in PntBrowser.
The real-time information includes latest refreshing data, status and quality of measuring point
concerning production process.A user can stop refreshing of measuring point through PntBrowser,
set up manual value or compulsory setting/reset, compulsory alteration of quality. The basic
information panel of point record displays the basic configuration information of measuring point,
modification disabled.
Real-time information panel of point record displays the real-time data value, status and quality of
measuring point.
The hardware information panel of point record displays the hardware configuration contents of
measuring point, modification disabled.
The alarm parameter panel of point record displays the alarm configuration information of
measuring point, modification disabled.
Fig. 4-14 Basic panel of point record Fig. 4-15 Real-time information panel of point record
EDPF-NT Distributed Control System
27
Fig. 4-16 Hardware information panel of point record Fig. 4-17 Alarm parameter panel of
point record
4.4.2 Classification schedule of point records
Measuring points can belong to different subsystems and types (temperature, pressure, flow,
etc.). Each parameter attribute includes character word. Using character word properly can
screen the parameters with relevant attribute characters in database efficiently and display in
schedule.Classification schedule can also organize display panels as per other attributes, e.g.
analog quantity, digital quantity, alarm point, stop scanning, timeout, measuring point sensor error,
etc.
Fig. 4-18 Classification schedule of measuring point
4.5 Algorithm browser
Algorithm browser (AlgDisplay) is a tool of EDPF NT distributed control system to provide
functions of monitoring and commissioning for site debugger.A debugger can view the real-time
information of various algorithms in controller, real-time value and real-time status of invocation
point, parameters of on-line setting algorithm and send various operator commands through this
on-line browser.
Algorithm browser can be called out from application toolbar, control logic commissioning panel
and point record panel.
EDPF-NT Distributed Control System
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Fig. 4-19 Algorithm browser
Using algorithm browser can modify the constant parameters of algorithm, send various operating
commands, call up PntBrowser, and view the information of invocation point of algorithm.
4.6 History trend browser
The history trend browser (hsrt) is an important display functional software of history data in
operator station of EDPF-NT Plus system.This function displays the history data of measuring
point in curves and tables.
4.6.1 History trend window:
A user can open any number of history data curve windows, and display up to 4 curve windows,
while each window can be defined with different foreground color and background color, and
each window displays up to 8 history curves of different colors. Each window can zoom up display
curve separately, just clicking the left button on panel, drag parameters to the target window, and
query the history curves easily.
4.6.2 History data retrieval
History data retrieval program (hsr_Retriever) provides query interface to operator in list to
display the alarm and event data incurred.
The functional zones of history data retrieval window involve time configuration, filtering condition
configuration, server configuration and alarm/event retrieval results.
History retrieval results can be screened through configuration of filtering conditions against
retrieval results.
History retrieval results can export alarms and events into different data files through command
"file"-"export".
Fig. 4-20 History trend browsing Fig. 4-21 History data retrieval panel
EDPF-NT Distributed Control System
29
Chapter V Engineer station software of EDPF-NT
5.1 Project Organizer (PO) integrating development style
Aiming at multiple domain network environment supported by EDPF-NT, a global engineer station
can configure and maintain multiple DCS subsystems in the meanwhile, and the system can
provide Project Organizer of the latest design.
Project Organizer (PO) is the project organization tool of EDPF-NT system, running on engineer
station, used for project management, domain configurations in project, station configurations,
management of database point, card configurations, management of SAMA chart configurations
and process image, etc.
Project Organizer can provide convenient on-line operation aiming at active project, e.g.
uploading and downloading of various data files. An engineer station can only have one active
project, and the operations including uploading and downloading are aimed at the active project.
Any project can be switched into active project.
PO can support distributed control system configuration plans of different network topology
structures.
5.1.1 Menu and toolbar of Project Organizer
Menu and toolbar of PO include the common tools of project management (Fig. 5-1).
Fig. 5-1 Toolbar of Project Organizer
5.1.2 Project column of Project Organizer
Use the project column by the left of PO window (Fig. 5-2, Fig. 5-3) to switch various functions of
Project Organizer.
Fig. 5.2 Fig. 5.3
EDPF-NT Distributed Control System
30
5.1.3 Primary functions of Project Organizer
Project management Create, delete and switch over the whole project.
Domain management Create, modify and delete all domains in project.
Point record editing Create, modify and delete measuring point.
Safety management Configure security group and device group of project.
Point group management Create, modify and delete point groups in project.
Station management Create, modify, delete, set up and configure all stations in project.
Fig. 5-4 Project Organizer panel
5.2 Graphic control configurator
The control configuration of EDPF-NT is simple and prompt. The control configuration platform
based on Microsoft Visio supports full graphic control configuration language like SAMA chart and
logic chart. It is convenient to realize customized algorithm.
Graphic control configurator is the tool of EDPF-NT system engineer station to control logic and
I/O card configuration, with features as follows:
Use the full graphic charting interface of graphic design software Macrosoft Visio to draw SAMA
chart directly;
Provide algorithms library with sophisticated functions to users to realize various control logic;
Dedicated compilation tool can convert SAMA chart compiling into target files to be used in
control stations.
Dedicated crossover kit can convert SAMA chart into process images to be used in MMI station
for real-time monitoring and debugging.
5.2.1 Configuration process of SAMA chart
SAMA chart can be distinguished into logic chart and card chart. Among others, the logic chart is
composed of control algorithm, while the card chart is composed of card algorithm. The
configuration processes are slightly different.
EDPF-NT Distributed Control System
31
The the above flow charts, the graphic files generated from editing are referred to as SAMA
charts with file name extension VSD.
The files generated from configuring and compiling (storing) SAMA charts are referred to as
target files with extension SAMA, as binary data files to be downloaded to DPU station.
The files generated from converting SAMA charts are referred to as process image files with
extension GOC, as binary data files to be downloaded to MMI station.
In configuring and compiling SAMA chart, according to the connection among algorithms, the
compiling tool will also create auto intermediate point in the system database of project.
5.2.2 Algorithm library
EDPF-NT system control configuration software provides algorithm library specially developed for
control logic configuration to users. The algorithm libraries include 4 categories, i.e. analog
quantity algorithm, digital quantity algorithm, I/O card and customized algorithm. Algorithm library
includes various advanced modules of control algorithm, e.g. self-correcting PID regulator,
self-adaptive control, Smith estimator. All algorithms are packed in modular, displayed as icon,
and distinguished in types. In using, merely drag them to panel and link with lines.The
configuration process is simple and efficient. Modulating control and switching value control
algorithm can be realized in the same control configuration panel, thus provide the most
immediate and powerful tool for learning about the whole control flow in a better way.
Panel 5-5 EDPF-NT algorithm library
The control logic compiling process generates standard SAMA chart debugging panel, which can
be accessed conveniently with right click of mouse on device process panel of operator station to
query logical configuration simply and promptly.
On the displayed panel, the relationship among algorithms is really visual. Open window can be
used to display the detailed contents of various algorithms, relationship of major input/output and
algorithm status (auto/manual) visually. It is also possible to call out the main parameters of this
algorithm for further adjustment. On logic chart, in addition to displaying the temporal states of
each switching value visually, it can also enforce the switching value as designated state (0 or 1)
manually, so as to realize simulated debugging of logical correlation.
EDPF-NT Distributed Control System
32
Fig. 5-6 SAMA configuration panel Fig. 5-7 SAMA debugging panel
Fig. 5-8 Open window displaying detailed algorithm contents
EDPF-NT Distributed Control System
33
Chapter VI Storage and retrieval of history data, alarm
information and event information
HSR has extremely significant function in EDPF NT distributed control system. It adopts revolving
door compression technique to collect and save parameters of production process or derived
data, including the real-time data, warning message, SOE event queue and operation record of
analog quantity and digital quantity, and save in the medium. The memory capacity of single unit
reaches 100,000 points, and redundant configuration is supported.
Use project manager to configure HSR and point records, and generate configuration file and
survey point list to be used in history station.The history station collects and saves the historical
data and alarm data during production control based on configuration file and measuring point list,
and provides services to other MMI stations including operator station and report station as server,
so as to display history trend curve and alarm historical information list, and develop running
statement.
HSR can also serve as operator station, engineer station, report station and OPC server
concurrently.
Fig. 6-1 History trend display
HSR software is a supporting service software with functions to provide history data storing and
retrieval service to interactive workstations on network, e.g. data collection, communication
management and file transmission, etc.
EDPF-NT Distributed Control System
34
Chapter VII Report function
The report station can achieve three types of reports: regular tabling, incident remembrance and
temporary tabling. Regular tabling and incident remembrance can operate multiple reports in the
meanwhile. A lot of report parameters are optional for users,e.g.: the end of a report can be a
designated moment in one day, or the end of a day or month. Thee period and times of data
collection pre-/post-incident remembrance are specified by users. The data created by report
shall be subject to statistical treatment, e.g.: averaging, integrating, maximum, minimum, etc. The
data created by report can be saved in medium. A report can be printed automatically and
promptly or as required manually. Printing process can be intervened manually, e.g.: suspend,
resume, cancel the current printing etc.
EDPF-NT Distributed Control System
35
Chapter VIII Layered comprehensive on-line
self-diagnostics
For the purpose to improve DCS reliability, EDPF-NT implements multi-layer system software and
hardware on-line self-diagnostics at background continuously, so as to detect, alarm and process
system failure timely. Operator station provides specific diagnostic panel to display the running
status of each section of system, and refresh in real time.
The comprehensive on-line self-diagnostics of EDPF-NT include: on-line diagnostics of
interactive workstation, on-line diagnostics of network communication equipment, on-line
diagnostics of controller running status, on-line diagnostics of all smart I/O modules and I/O
channels, on-line diagnostics of power system.
Fig. 8-1 Layered comprehensive on-line self-diagnostics
Fig. 8-2 Panel of comprehensive on-line self-diagnostics
EDPF-NT Distributed Control System
36
Chapter IX Distributed process control station (DPU)
Distributed process control station (DPU) is the most basic control unit of EDPF-NT. Among
others, the primary/standby controllers adopt embedded fanless-design low-power
high-performance computer, built-in LINUX operation system, real-time multitask kernel and
embedded configuration control software, which have combined functions of network
communication, data processing, sequential control, discrete control, sequential control and
batch processing organically to organize stable and reliable process control system. The
dedicated communication coprocessor polls and controls all on-line I/O subsystems in high speed
through expanded input/output interface EIO. The built-in GPS clock synchronous signal interface
ensures the clock synchronization of process control station to accuracy of millisecond level.
DPU supporting service software functions also include task schedule, I/O management,
communication processing, control algorithm calculation and system diagnostic. The process
control station controller can configure 5 independent arithmetic and control zones, while the
computation cycle of each control zone can be configured independently with minimum value of
20 ms.
The distributed process control station (DPU) links I/O subsystems via high-speed industrial
fieldbus. When using traditional IOBUS bus, it can link up to 64 I/O modules. Each distributed
process control station (DPU) is a small control system. It can realize true distributed control or
processing.
The process channel interface of new process control station of EDPF-NT has broken through
traditional simulated input-output mode, and can be compatible for the all-digital input-output
mode of various equipment and execution level distributed processing mode of instruments.
9.1 DPU controller
DPUIII controller and DPUIV controller of EDPF-NT system are the latest advanced controllers of
this Company featured with small size, high performance, convenient maintenance and super
reliability.
9.1.1 Technical features
Small size, high performance
DPU module has integrated the primary CPU, I/O communication control unit, dual-network card,
shared or exclusive EIO bus interface and GPS module. DPU controller has the same size of I/O
module.
It adopts X86 high performance but low-power CPU with brilliant performance and capable to
satisfy various project demand.
Overlapping processing super real-time performance
DPU controller adopts collaborative work mechanism and structure with multiple CPU
overlapping processing plus CPLD hardware programmable support chip.
The host processor is referred to as the control calculation CPU, liable for key tasks like control
logic processing and real-time data releasing.
Slave processor is referred to as I/O data administration CPU, liable for I/O communication tasks
with large system cost, e.g. data collection and processing, data collection and output of
hardware I/O channels.
EDPF-NT Distributed Control System
37
The host processor and slave processor exchange data in high speed via dual RAM for parallel
processing, which has efficiently improved the speed of data processing, and ensured the
deterministic treatment capacity of I/O data of controller and design capacity of control algorithm.
Complex programmable controller CPLD realizes complex logic like cyclic task dispatching
hardware timer and I/O bus switching, double unit monitoring and switching, GPS hard clock
synchronization processing, and mutual repulsion of dual RAM access, which has shared the
tasks in controller, simplified hardware structure, and ensured the reliability and rapidity of double
unit monitoring and switching.
The structural diagram of controller shall be as follows:
PC104/ISA总线
GPS模块CPU
主CPU
主CPU并口
GPS
信号接
收发送
并口(下载)
从CPU
单片机M68302
铁电存储器 双口RAM
上位机控制命令、
监控数据
2个以太网口
铁电控制逻辑
和I/O模块交换数据
程序
存储
器
485转换模块
接收卫星信号
SRA
M缓
存
双口RAM控制逻辑控制命令交换逻辑
ISA总线接口逻辑
CPLD EPM3128 485数据处理
从CPU
主CPU
Fig. 9-1 System structure of controller
Multiple redundancy, safe and reliable
DPU controller adopts the mode of primary/standby redundancy, all MCN network interface, EIO
network interface, IOBUS bus interface, power and significant I/O channels have redundancy
design, which has greatly improved system reliability.
Modular structure, convenient for maintenance;
It adopts modular design, which is composed of DPU units and base plate. DPU modules have
standard European sockets, the primary/standby station can be swapped independently. Both
installation and replacement are convenient and safe.
Reliable DC redundant wide-range power supply
Receive two ways of wide-range DC18-72V power inputs, realize redundant switching internally,
and ensure reliability of power.
Design of full isolation and high anti-interference to ensure reliable operation
Adopts DC/DC internally to insulate from power and I/O communication network, hardware and
software with multiple anti-interference and fault-tolerance correction capability.
Safe and reliable data storage
Adopt CF card to save configuration data without battery, which can ensure permanent storage of
data.
Convenient I/O module connection
In addition to provide terminal I/O outlet, the module base also provides two DB25 I/O standard
interfaces, which can merge with module base directly for convenient panel assembling and
installation.
EDPF-NT Distributed Control System
38
Favorable power and grounding isolation, hot pluggable
9.1.2 Technical parameters of DPU controller
Technical parameters of DPU controller
Power supply Rated redundancy 24~48 VDC, redundant wide-range 18~72
VDC
Power consumption <10W。
Ripple wave <5%
Processor model 500 MHz pentium low-power CPU
RAM 256M
Nonvolatile memory Electronic harddisk: 256M Compact Flash
Ethernet port 2 ×RJ45 twisted-pair interface, 10 M/100M auto-adapted
EIO bus interface Expanded input/output bus interface (DPUIV)
IOBUS bus interface 2 Mbps fieldbus interface + high precision synchronous clock
impulse circuit
Capacity of I/O
subsystem ≤ 64 smart monitoring and controlling modules
Communication protocol
of IOBUS bus
HDLC synchronous data link network transmission protocol,
half-duplex
Communication baud
rate 3 Mbps, 1.5 Mbps, 750 kbps, 375 kbps optional
Switching time of
primary/standby
controllers
<10ms
Network isolation voltage 500V
Serial interface 1: RS232 standard, DB9 needle interface, debugging exclusive
Keyboard interface PS2 keyboard interface, debugging exclusive
Display interface DB15 VGA interface, debugging exclusive
GPS interface
Terminal type, distinguished into GPS and PPS, RS485
standard, GPS communication compatible with NEMA0183
standard or East China Grid GPS adusting time protocol, baud
rate supporting 4800 or 9600, N, 8, 1.
Environment temperature -20~+ 60 ℃ (fan) or-20~50 ℃ (fanless)
Relative humidity 5%~90%
Physical dimensions of
DPU controller DPUIII: 80mm (W)×190 (H)×170mm (D)
Size of controller base DPUIII: 190mm (L)×244mm (W)×30mm (H)
9.1.3 Profile and structure of DPU controller
EDPF-NT Distributed Control System
39
Fig. 9-2 DPUIII redundant controller module Fig. 9-3 DPUIII controller panel
Fig. 9-4 DPUIV redundant controller module
9.2 Smart I/O modules
Fully dispersed intelligent I/O modules has intensified mechanic electrical protection capacity and
high reliability reflected in aspects as follows:
All I/O modules adopt double-circuit DC power supply
Metal case whole sealing reinforced structure with features of dust-proof, static-free,
anti-electromagnetic interference. Maintenance-free is achieved in life-cycle in deed.
Unique PTC electrical protection technology, measuring channel capable to 250 VAC/DC AC
signal free of damage;
I/O channels isolated from external electrics, field interfering source blocked. Signal isolation,
power isolation and communication isolation, triple isolation measures enabling system with
powerful interference-free feature;
The surfaces of module circuit board and components are processed with special paint with
featured of mould-proof, moisture-proof and salt fog resistance;
Use terminal/module integrated technology first of all, which is convenient to system
installation, service and maintenance.
EDPF-NT Distributed Control System
40
Fig. 9-5 Structural diagram of integrated terminal module
The base of I/O modules is combined with outlet terminal of module, power supply of module
(double-way 24 VDC) accesses from base, where has redundant IOBUS bus used for
communication between controller and module. The base is connected to module through middle
two groups of sockets to realize transmission of power supply and signal.
9.2.1 Analog input module
Model: EDPF-AI8 (mA)/EDPF-AI16 (mA)/EDPF-AIH8/EDPF-AIH16
Modulating measurement module EDPF-AI8 (mA)/EDPF-AI16 (mA) is mainly used for current
measurement in range of 0~20 mA, or voltage signal in range of 0~10 V. Current signal passes
250 Ω precise sampling impedance, and supplies system after amplification of meter amplifier
circuit and A/D converter and a/d conversion. After adding redundant recuperation board, it can
realize module and channel redundancy. Modulating measurement module
EDPF-AIH8/EDPF-AI16 supports HART bus protocol.
Characteristics of EDPF-AI8 (mA)/EDPF-AI16 (mA)
8/16 channel 0-20 mA current input,
0-10 V voltage input
Two-way sensor/transmitter
working mode
Support HART bus
Interface insulated with system
Hardware watchdog
Support hot plug
Real-time status display
Support module redundancy
Open circuit/short-circuit detection
Over-current protection, 24 VDC
power supply reverse protection
Characteristics of EDPF-AIH8/EDPF-AIH16
Compatible with HART protocol standard, channel rate of single HART as 1200 bps;
Each HART channel can link up to 15 transmitters; usually one-to-one connection;
HART protocol transition card can process 8/16 HART channels in the meanwhile;
Channel scanning speed at least 2 times/second per channel;
Support transmitter and HART operating mechanism;
Compatible with HDLC control protocol, achieve connection with existing DPU;
EDPF-NT Distributed Control System
41
HART protocol transition card provides transparent channel, and DPU can configure
HART transmitter directly;
Circuit board provides JTAG interface, convenient for upgrading and debugging;
Internally optional series connection is compatible with 24 Vdc power supply of HART
standard (double-circuit redundancy) to supply transducer.
Technical criteria of analog input module
EDPF-AI8 (mA)/EDPF-AI16 (mA)
Description Statement
Input characteristics
Number of detection
channels
8/16 lines of differential inputs
A/D conversion
accuracy
16 bits
Range ability 0~20mA/0~10V
Measuring precision 0.1%@25℃, F.S
Signal multiplication
times
1
Data mode rejection Superior to 70 dB (DC to AC 60 Hz)
Differential mode
rejection
Superior to 60 dB
Current sampling
impedance
250Ω
Sampling rate 5 times per second
Thermal transient ±25ppm/℃
Isolation
Channel isolation
voltage
400V
Communication
isolation voltage
500V
Communication
Communication
protocol
HDLC, synchronous data transmission, half-duplex
Communication rate 2Mbps/750Kbps/375Kbps/187.5Kbps
Power supply
Working voltage Redundancy 24 VDC±5 %
Power consumption
(Max)
4.56W@24VDC (under condition of 16 channels supplied
at 20 mA in the meanwhile)
Working environment
Operating
temperature
0℃~60℃
Operating humidity 5% ~90 % relative humidity, non-condensing
Storing temperature -40℃~85℃
Storing humidity 5% ~95 % relative humidity, non-condensing
EDPF-NT Distributed Control System
42
Physical characteristics
Physical dimension 80mm (W)×190 (H)×170 mm (D)
Protection grade IP50
AI redundant recuperation board
Description Statement
Input/output characteristics
Number of detection
channels
16-line current inputs, 16-line redundant module A
voltage output, 16-line redundant module B
voltage output
Input range Current 0~20 mA
Output range Voltage 0~10 V
Output precision 0.1%@25℃, F.S
Channel current restriction 50mA
9.2.2 Thermistor measurement module
Model: EDPF-RTD8/RTD16
Thermistor measurement module EDPF-RTD8/RTD16 is mainly used for signal measurement of
thermistor (PT100, CU50) in measuring principle of balancing bridge to convert impedance of
thermistor into relevant voltage, and supplies system after amplification of meter amplifier circuit
and A/D converter and a/d conversion.
Characteristics:
8/16 channel thermistor inputs
Interface insulated with system
Support disconnection detection
Hardware watchdog
Support hot plug
Real-time status display
Over-current protection, 24 VDC
power supply reverse protection
Technical criteria of thermistor measurement module
EDPF-RTD8/RTD16
Description Statement
Input characteristics
Number of detection channels 8/16-line thermistor inputs
Range ability 0-300Ω
Measuring precision 0.1%@25℃, F.S
A/D conversion accuracy 16- bit
Signal multiplication times 50
Data mode rejection Superior to 70 dB (DC to AC 60 Hz)
Differential mode rejection Superior to 60 dB
Sampling rate 5 times per second@ Max
Thermal transient ±25ppm/℃
Isolation
Channel isolation voltage 400V
Communication isolation
voltage
500V
EDPF-NT Distributed Control System
43
Communication
Communication protocol HDLC, synchronous data transmission, half-duplex
Communication rate 2Mbps/750Kbps/375Kbps/187.5Kbps
Power supply
Working voltage Redundancy 24 VDC±5 %
Power consumption 4.32W@24VDC
Working environment
Operating temperature 0℃~60℃
Operating humidity 5% ~90 % relative humidity, non-condensing
Storing temperature -40℃~85℃
Storing humidity 5% ~95 % relative humidity, non-condensing
Physical characteristics
Physical dimension 80mm (W)×190 (H)×170 mm (D)
Protection grade IP50
9.2.3 Thermocouple measurement module
Model: EDPF-TC8R/EDPF-TC16R/EDPF-TC16
Thermocouple modulating measurement module EDPF-TC8R/EDPF-TC16R/EDPF-TC16 is
mainly used for processing multi-voltmeter thermocouple voltage from field and voltage input
signal s at multi-volt level.
Characteristics
8/15/16-channel thermocouple or
multi-volt signal input
EDPF-TC8R channel 9 as input of
cold-junction compensation
EDPF-TC16R channel 16 as input
of cold-junction compensation
Support disconnection detection
Interface insulated with system
Hardware watchdog
Support hot plug
Real-time status display
Over-current protection, 24 VDC
power supply reverse protection
Technical criteria of thermocouple measurement module
EDPF-TC8R/EDPF-TC15R/EDPF-TC16
Description Statement
Input characteristics
Number of detection channels 8/15/16 lines of differential inputs
Signal type Thermocouple (K, E, N, J, T) or multi-volt voltage signal
Range ability ±80mV
Measuring precision 0.1%@25℃, F.S
A/D conversion accuracy 16 bits
Temperature measurement
range cold junction
compensation
-50~270℃
Signal multiplication times 100
Data mode rejection Superior to 70 dB (DC to AC 60 Hz)
EDPF-NT Distributed Control System
44
Differential mode rejection Superior to 60 dB
Sampling rate 5 times per second
Thermal transient ±25ppm/℃
Isolation
Channel isolation voltage 400V
Communication isolation
voltage
500V
Communication
Communication protocol HDLC, synchronous data transmission, half-duplex
Communication rate 2Mbps/750Kbps/375Kbps/187.5Kbps
Power supply
Working voltage 24VDC±5%
Power consumption 4.08W@24VDC
Working environment
Operating temperature 0℃~60℃
Operating humidity 5% ~90 % relative humidity, non-condensing
Storing temperature -40℃~85℃
Storing humidity 5% ~95 % relative humidity, non-condensing
Physical characteristics
Physical dimension 80mm (W)×190 (H)×170 mm (D)
Protection grade IP50
9.2.4 Modulating output module
Model: EDPF-AO8/EDPF-AO8D
Modulating output module EDPF-AO8/EDPF-AO8D provides 8-line 4~20 mA signal outputs. It is
mainly used to convert the numerical values of calculations of controller into analog value output
via D/A converter, so as to control the operating mechanism to conduct intended action. After
adding redundant recuperation board, EDPF-AO8D module can realize module and channel
redundant configuration.
Characteristics
8-channel isolated 4~20 mA
output
Redundant current output
Interface insulated with system
Hardware watchdog
Support hot plug
Real-time status display
Over-current protection, 24 VDC
power supply reverse protection
Technical criteria of modulating output module
EDPF-AO8/EDPF-AO8D
Description Statement
Input characteristics
Number of channels 8
Range of signal 4~20mA
Output precision 0.1%@25℃,F.S
EDPF-NT Distributed Control System
45
D/A conversion accuracy 16 bits
Thermal transient Max±50ppm/℃
Load capacity (Max) Max.1KΩ@24VDC
Isolation
Channel isolation voltage 500V
Communication isolation
voltage
500V
Communication
Communication protocol HDLC
Communication rate 2Mbps/750Kbps/375Kbps/187.5Kbps
Power supply
Working voltage 24VDC±5%
Power consumption (Max) 11.04W@24VDC (complete circuit output 24V)
Working environment
Operating temperature 0℃~60℃
Operating humidity 5% ~90 % relative humidity, non-condensing
Storing temperature -40℃~85℃
Storing humidity 5% ~95 % relative humidity, non-condensing
Physical characteristics
Physical dimension 80mm (W)×190 (H)×170 mm (D)
Protection grade IP50
AO redundant recuperation board
Description Statement
Input/output characteristics
Number of detection
channels
8-line redundant module A voltage input, 8-line redundant
module B voltage input, 8-line select-high current output
Input span 4~20mA
Output range 4~20mA
Output precision 0.1%@25℃, F.S
9.2.5 Current output multi-circuit control module
Model: EDPF-ACT4
EDPF-ACT4 is multi-circuit control module of current output type, with 8 analog input channels
and 4 analog output channels. The performance index of analog input channel is identical module
AI (mA), capable to access current and voltage signals, use two-wire system to supply transducer
directly with configuration mode the same as module EDPF-AI (mA), and the performance index
of analog output channel identical to module EDPF-AO8.
Current output type multi-circuit control module EDPF-ACT4 is mainly used for output regulation
of control circuit, while the analog input channel is used for detection of position feedback of
operating mechanism, and the analog output channel is used for driving operating mechanism.
Each EDPF-ACT4 module can provide 4 independent circuit output controls respectively.
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Characteristics
8-channel 0~20 mA current
input/0~5V voltage input,
4-channel 4 ~ 20 mA current
output
Two-way sensor/transmitter
working mode
Interface insulated with system
Hardware watchdog
Support hot plug
Real-time status display
Over-current protection, 24 VDC
power supply reverse protection
Technical criteria of current output type multi-circuit control module
EDPF-ACT
Description Statement
Input/output characteristics
Number of detection
channels
8-line current/voltage input, 4-line current output
Range ability Input 0 ~ 20 Ma/0~V, output 4 ~ 20 Ma
Measuring precision 0.1%@25℃, F.S
A/D conversion accuracy 16 bits
Output precision 0.1%@25℃, F.S
D/A conversion accuracy 16 bits
Signal multiplication
times
2
Data mode rejection Superior to 70 dB (DC to AC 60 Hz)
Differential mode
rejection
Superior to 60 dB
Current sampling
impedance
250Ω
Sampling rate 5 times per second
Load capacity (Max) Max.1KΩ@24VDC
Thermal transient ±25ppm/℃
Isolation
Channel isolation voltage 400V
Communication isolation
voltage
500V
Communication
Communication protocol HDLC, synchronous data transmission, half-duplex
Communication rate 2Mbps/750Kbps/375Kbps/187.5Kbps
Power supply
Working voltage 24VDC±5%
Power consumption
(Max)
6.24 W@24VDC (under condition of 16 channels supplied
at 20 mA in the meanwhile)
Working environment
Operating temperature 0℃~60℃
Operating humidity 5% ~90 % relative humidity, non-condensing
EDPF-NT Distributed Control System
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Storing temperature -40℃~85℃
Storing humidity 5% ~95 % relative humidity, non-condensing
Physical characteristics
Physical dimension 80mm (W)×190 (H)×170 mm (D)
Protection grade IP50
9.2.6 Pulse output multi-circuit control module
Model: EDPF-CT4
EDPF-CT4 is pulse modulation output type multi-circuit control module in the EDPF distributed
high-speed smart monitoring and controlling network, realizes the function of 4 servo-amplifiers in
one module, and modulates output impulse signals, so as to position operating mechanism
accurately and in a better way, then achieve favorable control quality of the whole control circuit.
The previous 4 channels of module are AIs (used for inputs of position feedback), and later 8
channels as DOs for output of 4 circuits of depropagation pulsed signal respectively.
For the control principle of circuits, taking one circuit as example, DPU sends control demand
SVX of module CT4 as target value of AI. Two ways of DOs output different status based on the
customized maximum permitted error V1, inertia error V2 (V2 > V1) and input analog amount AI,
so as to control the absolute value of difference between input analog amount AI and normal
value SVX less than V1. CT4 card is mainly applicable to corotation and reverse rotation of motor
depending on control valve positions, so that the value of valve position reaches the industrial
field of set-point. The DO contact current capacity of CT4 card is small, and connected to the
control circuit of motor only through intermediate relay.
It used pulse output control. As compared to modulating output control, the merits mainly reflect
on operating mechanism capable to keep position when module losing power, which can improve
safety feature. In the meanwhile, due to tolerance V1, inertia error V2, impulse duration Tm and
pulse spacing Ts in each circuit of CT4 card can be configured (in signal type domain of DPU
order signal) flexibly and separately, it performs better both in capacity and flexibility than the
traditional servo-amplifier.
For input analog amount AI, A/D collection is unipolar, input range as 10V, and AI including three
input modes: (1) DC voltage signal (2) DC current signal (3) transmitter signal, with specific
configuration method as per later instruction of main-board operations, basicly the same as AI
module.
8-line digital outputs have two modes: ① active output, and ② passive output, and the normal
state of output is normally on.
In addition, CT4 module also has power-fail protective function. When the module is re powered,
output command AO (from DPU) and DO keep the values at power-fail, till initialization completed
and calculation returning to normal. Once initialized, algorithm parameters SVX, V1 and V2 will
not be changed, even after power-fail and repowering, still keep the original value, but only a user
can change its value by sending modification command from upper computer to CT4 card.
In the same way, CT4 module and EDPF monitoring and controlling network have realized rigid
electric isolation, enabled CT4 module at suspended status, and prevented common-ground
interference of various modules and module to network efficiently. The input/output channels of
CT4 module and kernel CPU and peripheral circuit of the same module also have realized strict
electric isolation, ensured CPU capable to work stably for long time under harsh environment,
EDPF-NT Distributed Control System
48
and enabled the upper computer to diagnose field fault and contingency easily.
Characteristics
4-channel 0~20 mA current
input/0~5 V/0-10V voltage input,
8-channel active/passive digital
outputs
Input two-way sensor/transmitter
working mode
Input/output interface isolated to
system electrics
Over-current protection, power
supply reverse protection
Hardware watchdog
Support hot plug
Real-time status display
Technical criteria of pulse modulation output type multi-circuit control module
EDPF-CT4
Description Statement
Input/output characteristics
Number of detection channels 4-line current/voltage input, 8-line digital output
Input range Input 0~20mA/0~5V/0~10V,
Measuring precision 0.1%@25℃, full range
A/D conversion accuracy 16 bits
Output mode Active or passive optional
Output current restriction 120mA
Contact capacity 1A@24VDC
Switch life 2x10e5 times
actuation/conduction time 3ms
Release/cut-off time 3ms
Signal multiplication times 1 or 2
Data mode rejection Superior to 70 dB (DC to AC 60 Hz)
Differential mode rejection Superior to 60 dB
Current sampling impedance 250Ω
Sampling rate 5 times per second
Load capacity (Max) Max.1KΩ@24VDC
Thermal transient ±25ppm/℃
Isolation
Channel isolation voltage 400V
Communication isolation
voltage
500V
Communication
Communication protocol HDLC, synchronous data transmission, half-duplex
Communication rate 2Mbps/750Kbps/375Kbps/187.5Kbps
Power supply
Working voltage 24VDC±5%
Power consumption (Max) 5 W@24VDC (under condition of 4 channels supplied at
20 mA in the meanwhile)
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Working environment
Operating temperature 0℃~70℃
Operating humidity 5% ~90 % relative humidity, non-condensing
Storing temperature -15℃~85℃
Storing humidity 5% ~95 % relative humidity, non-condensing
Physical characteristics
Physical dimension 80mm (W)×190 (H)×170 mm (D)
Protection grade IP50
Pulse output control algorithm of EDPF-CT4 pulse modulation output type multi-circuit control
module
The built-in servo algorithm module of module decides the outputs of pulse type digital quantity
DO1, DO2 through comparing the output signal of regulator and the position signal of operating
mechanism collected from modulating input. DO1 and DO2 are used for control over corotation
and reverse rotation of motor of operating mechanism respectively. DO1 is used for control over
corotation and increasing position value of feedback; and DO2 is used for control over reverse
rotation and decreasing the position value of feedback. The output algorithm of DO1 and DO2
shall be shown as the following diagram:
Fig. 9-6 Algorithm diagram of EDPF-CT4 pulse modulation output type multi-circuit control
module
Parameter specification
AI: input AI value
SVX: AI normal value, i.e. the AI value to be controlled and reached
V1: maximum error
V2: inertia error, i.e. the error caused by inertia of controller
Tm: impulse duration
Ts: pulse spacing
For different controllers, adjusting V1, V2, T1 and T2 can cause the absolute value of difference
between input value AI and normal value SVX less than V1.
Note: The outputs of DO2 and DO1 shall be eudipleural.
9.2.7 16-line digital input module
Model: EDPF-DI16/EDPF-DIE
DO2
221
DO1 AI-SVX V1
V2
Ts
DO1
Tm
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EDPF-DI16/EDPF-DIE is digital input module, which can acquire 16-line switching value status in
real time, and record the sequence and time of switching value state events. The resolution of
event time can reach 0.5 ms.
EDPF - DI16 module has lowpass digital filter. For digital quantity bouncing, the cutoff
frequency is 50 Hz, which can eliminate switching value bouncingless than 20 ms effectively.
EDPF - DIE module is the update of EDPF-DI16, and the digital quantity debouncing time is 4
ms. The resolution of event time can reach 0.3 ms.
The interface is insulated with system electrics, so as to prevent various module interfaces from
mutual interference.
16-channel digital inputs are dry contact inputs, and provide over-current and over-voltage
protection and reverse voltage protection, which can prevent module interface from damage in
case of accessing false signals.
EDPF-DI16/EDPF-DIE characteristics
16-line digital input channel
Dry contact input mode
Module power supply: +24VDC,
+48VDC, +110VDC (only for
module EDPF-DI16 (110V))
256 sequential event records
SOE resolution < 1 ms
50 Hz lowpass digital filter/4 ms
debouncing time
Isolation voltage between interface
and system: 1500 V
Interface over-voltage and
over-current,
Power supply reverse protection
Hardware watchdog
Support hot plug
Real-time status display
Technical criteria of digital input module
EDPF-DI16
Description Statement
Input characteristics
Number of detection channels 16-line digital input
Detection voltage
+24VDC
+48VDC
+110VDC Event recorder 256
Resolution of event time 0.5ms
Bandwith of lowpass digital filter 50Hz
Input response time 20ms
Isolation
Isolation voltage between
interface and system
1500V
Communication
Communication protocol HDLC, synchronous data transmission, half-duplex
Communication rate 2Mbps/750Kbps/375Kbps/187.5Kbps
Power supply
Working voltage 24VDC±5%
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Power consumption 2.16W@24VDC no-load
Working environment
Operating temperature 0℃~70℃
Operating humidity 5% ~90 % relative humidity, non-condensing
Storing temperature -50℃~65℃
Storing humidity 5% ~95 % relative humidity, non-condensing
Physical characteristics
Physical dimension 80mm (W)×190 (H)×170 mm (D)
Protection grade IP50
EDPF-DIE
Description Statement
Input characteristics
Number of detection
channels
16-line digital input
Detection voltage +24VDC
+48VDC Event recorder 256
Resolution of event time 0.3ms
Bandwith of lowpass
digital filter
250Hz
Input response time 4ms
Isolation
Isolation voltage between
interface and system
1500V
Communication
Communication protocol HDLC, synchronous data transmission, half-duplex
Communication rate 2Mbps/750Kbps/375Kbps/187.5Kbps
Power supply
Working voltage 24VDC±5%
Power consumption 2.16W@24VDC no-load
Working environment
Operating temperature 0℃~70℃
Operating humidity 5% ~90 % relative humidity, non-condensing
Storing temperature -50℃~65℃
Storing humidity 5% ~95 % relative humidity, non-condensing
Physical characteristics
Physical dimension 80mm (W)×190 (H)×170 mm (D)
Protection grade IP50
9.2.8 32-line digital input module
Model: EDPF-DI32
EDPF-DI32 digital input module can acquire 32-line switching value status in real time. It has
lowpass digital filter with cutoff frequency 50 Hz, which can eliminate switching value bouncing
EDPF-NT Distributed Control System
52
less than 20 ms effectively.
The interface is insulated with system electrics, so as to prevent various module interfaces and
interface to field from mutual interference.32-channel digital inputs are dry contact inputs, and
provide over-current and over-voltage protection, reverse voltage protection and strong current
sneaking protection, which can prevent module interface from damage in case of accessing false
signals.
Characteristics
32-line digital input channel
Dry contact input mode
Module power supply: + 24 VDC, +
48 VDC, + 110 VDC
50 Hz lowpass digital filter
Isolation voltage between interface
and system: 1500 V
Interface over-voltage and
over-current
Power supply reverse protection
Hardware watchdog
Support hot plug
Real-time status display
Technical criteria of digital input module
Description Statement
Input characteristics
Number of detection channels 32-line digital input
Detection voltage +24VDC
+48VDC
Bandwith of lowpass digital
filter
50Hz
Input response time 20ms
Isolation
Isolation voltage between
interface and system
1500V
Communication
Communication protocol HDLC, synchronous data transmission, half-duplex
Communication rate 2Mbps/750Kbps/375Kbps/187.5Kbps
Power supply
Working voltage 24VDC±5%
Power consumption 2.16W@24VDC no-load
Working environment
Operating temperature 0℃~60℃
Operating humidity 5% ~90 % relative humidity, non-condensing
Storing temperature -40℃~85℃
Storing humidity 5% ~95 % relative humidity, non-condensing
Physical characteristics
Physical dimension 80mm (W)×190 (H)×170 mm (D)
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Protection grade IP50
9.2.9 Digital input/output module
Model: EDPF-DIO32
Digital input/output module EDPF-DIO32 packs 16-line digital input card and 16-line digital output
card in a metal case to provide 16-line digital input channels and 16-line digital output channels.
The digital input interface of EDPF - DIO32 module has lowpass digital filter, with cutoff
frequency 50 Hz, which can eliminate digital quantity bouncing less than 20 ms effectively.
The interface is insulated with system electrics, so as to prevent various module interfaces from
mutual interference.
16-channel digital inputs are stem node inputs, and provide over-current and over-voltage
protection and reverse voltage protection, which can prevent module interface from damage in
case of accessing false signals.
16-line digital output channels can output 24 V digital quantity signals or dry contact output
optional.
Characteristics
16-line digital input channel
16-line digital output channel
Dry contact input mode
Active output or dry contact output
mode
Module power supply: + 24 VDC, +
48 VDC
50 Hz lowpass digital filter
Isolation voltage between interface
and system: 1500 V
Interface over-voltage and
over-current,
Power supply reverse protection
Highly reliable capability of
anti-electromagnetic interference;
Hardware watchdog
Support hot plug
Real-time status display
Technical criteria of digital input/output module
EDPF-DIO32
Description Statement
Product model DIO32
Input characteristics
Number of detection channels 16-line digital input
Detection voltage
+24VDC
+48VDC
+110VDC (only for module EDPF-DIO32 (110V))
Input filtering bandwith 50Hz
Input response time 20ms
Output characteristic
Output channel 16-line digital output
Output mode +24V
Output current restriction 120mA
Contact capacity 1A@24VDC
Switch life 2x10e5
actuation/conduction time 3ms
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Release/cut-off time 3ms
Isolation
Isolation voltage between interface
and system
1500V
Communication
Communication protocol HDLC
Communication rate 2Mbps/750Kbps/375Kbps/187.5Kbps
Power supply
Working voltage 24VDC±5%
Power consumption 2.64W@24VDC no-load
6.24 W@24VDC full load
Working environment
Operating temperature 0℃~60℃
Operating humidity 5% ~90 % relative humidity, non-condensing
Storing temperature -40℃~85℃
Storing humidity 5% ~95 % relative humidity, non-condensing
Physical characteristics
Physical dimension 80mm (W)×190 (H)×170 mm (D)
Protection grade IP50
9.2.10 Digital output module
Model: EDPF-DO16
Digital output module EDPF-DO16 has 16-line digital output channels. The interface is insulated
with system electrics, so as to prevent various module interfaces from mutual interference.
16-line digital output channels can output 24 V or 48 V switching value signals or dry contact
output optional.
Characteristics
16-line digital output channel
Active output or dry contact output
mode
50 Hz low-pass digital filter
Isolation voltage between interface
and system: 1500 V
Interface over-voltage and
over-current,
Power supply reverse protection
Highly reliable capability of
anti-electromagnetic interference;
Hardware watchdog
Support hot plug
Real-time status display
Technical criteria of digital output module EDPF-DO16
EDPF-DO16
Description Statement
Product model DO16
Output characteristic
Output channel 16-line digital output
Output mode +24V
Output current restriction 120mA
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Contact capacity 1A@24VDC
Switch life 2x10e5
actuation/conduction time 3ms
Release/cut-off time 3ms
Isolation
Isolation voltage between
interface and system
1500V
Communication
Communication protocol HDLC, synchronous data transmission, half-duplex
Communication rate 2Mbps/750Kbps/375Kbps/187.5Kbps
Power supply
Working voltage 24VDC±5%
Power consumption (Max) 1.92W@24VDC no-load
5.52W@24VDC full load
Working environment
Operating temperature 0℃~60℃
Operating humidity 5% ~90 % relative humidity, non-condensing
Storing temperature -40℃~85℃
Storing humidity 5% ~95 % relative humidity, non-condensing
Physical characteristics
Physical dimension 80mm (W)×190 (H)×170 mm (D)
Protection grade IP50
9.2.11 8-channel pulsed quantity measurement module
Model: EDPF-PI
EDPF-PI pulsed quantity measurement module has 8 lines of input pulse signal in total. The
interface is insulated with system electrics, so as to prevent various module interfaces from
mutual interference.
8-channel pulsed quantity inputs are stem node inputs, and provide over-current and over-voltage
protection and reverse voltage protection, which can prevent module interface from damage in
case of accessing false signals.
Characteristics
8-line pulsed quantity input channel
Dry contact input mode
Module power supply: + 24 VDC, +
48 VDC
Max. 4 * 10 E9 pulse count value
50 Hz lowpass digital filter
Isolation voltage between interface
and system: 1500 V
Interface over-voltage and
over-current,
Power supply reverse protection
Hardware watchdog
Support hot plug
Real-time status display
Technical criteria of pulsed quantity measurement module
EDPF-NT Distributed Control System
56
EDPF-PI
Description Statement
Input characteristics
Number of detection channels 8-line pulsed quantity input
Detection voltage +24VDC
+48VDC
Maximum pulse counting 4*10E9
Bandwith of lowpass digital
filter
50Hz
Input response time 20ms
Isolation
Isolation voltage between
interface and system
1500V
Communication
Communication protocol HDLC, synchronous data transmission, half-duplex
Communication rate 2Mbps/750Kbps/375Kbps/187.5Kbps
Power supply
Working voltage 24VDC±5%
Power consumption 1.92W@24VDC no-load
Working environment
Operating temperature 0℃~70℃
Operating humidity 5% ~90 % relative humidity, non-condensing
Storing temperature -15℃~85℃
Storing humidity 5% ~95 % relative humidity, non-condensing
Physical characteristics
Physical dimension 80mm (W)×190 (H)×170 mm (D)
Protection grade IP50
9.2.12 Steam-turbine speed measurement and over-speed protection module
Model: EDPF-SD1/EDPF-SD3
EDPF-SD is speed measurement and steam turbine protection module used exclusively for
steam-turbine electrohyraulic control system DEH, provides three-way speed measurement,
implements two-out-of-three logic on module, realizes two-out-of-three function, and provides
output signal of over-speed protection. In practical applications, it uses two EDPF-SD in the
meanwhile for hot stand-by redundancy.
Three-way speed signals speed1, speed2 and speed3 are sent to three independent waveform
shaping circuits, amplification module and square-wave producer, and calibrated through
standard time clock before precise calculation of speed value with precision of 0.4 rpm at 3000
rpm. After CPU having calculated three speed values, middle-out-of-three algorithm, the correct
EDPF-NT Distributed Control System
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speed value is selected for control and protection. In the meanwhile, the module has designed
with sophisticated over-speed protection logic to ensure the reliability and rapidity of over-speed
protection function.
Characteristics
Three-way steam-turbine speed
measurement channel (EDPF-SD1
as one channel)
Three-way oil switch signal input
103%OPC signal output
110%AST (to VC card)/110%AST
(to field) signal output
Isolation voltage between interface
and system: 1500 V
Hardware watchdog
Support hot plug
Real-time status display
Technical criteria of steam-turbine speed measurement and over-speed protection module
EDPF-SD1/SD3
Description Statement
Characteristics of input/output channel
Signal type of rotation speed input Sinusoid of inductive resistance probe,
square-wave of flux-sensitive probe
Maximum rotating speed signal
(peak-peak value)
30V
Minimum rotating speed signal
(peak-peak value)
0.4V~0.8V
Measurable signal maximal rate 7500 rpm
Tooth number of tachometer disk 1~300
Measuring precision of rotation speed
signal
Rotation=3000 rpm,<=0.4 rpm
Speed measurement time Rotation speed <= 200 rpm, two signal periods
Rotation>=200 rpm, 20mS
Digital input characteristics
Input channel 6 lines
Signal type Dry contact
Signal detection voltage 24VDC
Digital output characteristics
Output channel 3 lines
Output signal type 1 line of relay dry contact
2 lines of active 24 VDC
Isolation
Communication isolation voltage 500V
Isolation voltage between interface
and system
1500V
Communication
EDPF-NT Distributed Control System
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Communication protocol HDLC, synchronous data transmission,
half-duplex
Communication rate 2Mbps/750Kbps/375Kbps/187.5Kbps
Power supply
Working voltage 24VDC±5%
Power consumption (Max) 5.52W@24VDC no-load
Full load
Working environment
Operating temperature 0℃~70℃
Operating humidity 5% ~90 % relative humidity, non-condensing
Storing temperature -15℃~85℃
Storing humidity 5% ~95 % relative humidity, non-condensing
Physical characteristics
Physical dimension 80mm (W)×190 (H)×170 mm (D)
Protection grade IP50
9.2.13 Steam-turbine electric-tuning valve servo module
Model: EDPF-VC
EDPF-VC module is smart servo power amplifier module specially designed for steam-turbine
electrohyraulic control system DEH, and received control demand of controller to drive
electro-hydraulic converter directly after power amplification. EDPF-VC module is integrated with
LVDT signal transducer, implements select-high automatically, forms close circuit of valve
position through internal variable PI regulator, and realizes accurate control over valve position.
Through hyperterminal, it can configure LVDT electric zero point and fullness conveniently to
adjust control parameters. EDPF-VC module takes a full consideration of the compatibility of
fire-resistant oil DEH and turbine oil DEH. The software part of module is completely consistent,
and hardware part just needs to replace output recuperation board based on servo-valve of
different input signal types.
EDPF-VC module provides displacement transducer interface, while the transducer provides
electric signal in linear ratio to displacement and realizes control over oil servo motor.
The output signals of EDPF-VC (three-wire) series module include-10V~+10V,-10mA~+10mA
and 4~20 mA.
EDPF-VC card has general terminal communication interface. A user can configure and check
functions of VC module in Windows hyperterminal software via RS232 communication cable,
including zero point and fullness adjustment, control parameter adjustment.
EDPF-VC card is designed with function of manual operation. When the auto/manual key on
standby manual operation panel is switched to manual, press increase or decrease button and
accelerate button to operate valve directly. The normal increase or decrease speed is 5%/min,
and accelerated increase or decrease speed as 35 %/min. Manual auto tracking VC card in
problem has been considered thoroughly.
When EDPF-VC card judges communication fault of upper computer (host of DPU station) or two
EDPF-NT Distributed Control System
59
ways of LVDTs in fault, EDPF-VC card sends request for emergency manual operation, indicator
"request for manual operation" on standby manual operation panel on, then switch auto/manual
key to manual according to circumstance, and operate the valve directly (operation available in
case of communication fault; when two ways of LVDTs in fault, control valve closed completely).
Characteristics
Three-wire/six-wire LVDT
measurement interface
Single/double LVDT measuring
channel
LVDT sensor automatic fault
detection
Manual/auto switch
Manual increase/decrease
±10V/4~20mA/-10~10mA
modulating output
Isolation voltage between interface
and system: 1500 V
Hardware watchdog
Support hot plug
Real-time status display
Technical criteria of steam-turbine electric-tuning valve servo module
EDPF-VC
Description Statement
Modulating input/output characteristics
LVDT input Three-wire/six-wire
Current transducer input 4~20mA
Valve control signal output ±10V/4~20mA/-10~10mA
Display current output 4~20mA
Displacement detection
precision
0.1%@25℃, F.S
Output precision 0.1%@25℃, F.S
Digital input characteristics
Input channel 5 lines
Signal type Dry contact
Signel detection voltage 24VDC
Digital output characteristics
Output channel 1-way
Output signal type Relay dry contact or active 24 VDC optional
Isolation
Communication isolation
voltage
500V
Isolation voltage between
interface and system
1500V
Communication
Communication protocol HDLC, synchronous data transmission, half-duplex
EDPF-NT Distributed Control System
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Communication rate 2Mbps/750Kbps/375Kbps/187.5Kbps
Power supply
Working voltage 24VDC±5%
Power consumption (Max) 5.52W@24VDC no-load
Full load
Working environment
Operating temperature 0℃~70℃
Operating humidity 5% ~90 % relative humidity, non-condensing
Storing temperature -15℃~85℃
Storing humidity 5% ~95 % relative humidity, non-condensing
Physical characteristics
Physical dimension 80mm (W)×190 (H)×170 mm (D)
Protection grade IP50
9.2.14 Electric quantity measurement module
Model: EDPF-EM
EDPF-EM module can measure 8-line VAC signals (0~100 V), 8-line AC current signals (0~5 A)
or 16-line AC current signals (0~A) in the meanwhile based on different recuperation modules,
calculate the virtual values, mating voltages, phase angle between currents (power factor) and
voltage frequency. 8-line VAC signals and 8-line AC current signals are one-to-one mating.
Characteristics
16-line 0 ~ 2.91 V VAC input
channel
8-line current, 8-line voltage
measurement (matching with
EDPF-EM (recuperation board))
16-line current (0-5 A)
measurement (matching with
EDPF-EM2 (recuperation board))
Recuperation board converting
field voltage and current signals
through CT and PT isolation
Over-current protection, power
supply reverse protection
Hardware watchdog
Support hot plug
Real-time status display
Technical criteria of electric quantity measurement module
EDPF-EM main module
Description Statement
Input/output characteristics
Number of detection channels 16-line VAC input
Range ability 0~2.91V VAC
Measuring precision 0.1%@25℃, full range
Signal multiplication times 2
Data mode rejection Superior to 70 dB (DC to AC 60 Hz)
Differential mode rejection Superior to 60 dB
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61
Sampling rate 16 time every 20 ms
Isolation
Channel isolation voltage >2200Vac
Communication isolation
voltage
500V
Communication
Communication protocol HDLC, synchronous data transmission, half-duplex
Communication rate 2Mbps/750Kbps/375Kbps/187.5Kbps
Power supply
Working voltage 24VDC±5%
Power consumption (Max) 5W@24VDC
Working environment
Operating temperature 0℃~70℃
Operating humidity 5% ~90 % relative humidity, non-condensing
Storing temperature -15℃~85℃
Storing humidity 5% ~95 % relative humidity, non-condensing
Physical characteristics
Physical dimension 80mm (W)×190 (H)×170 mm (D)
Protection grade IP50
Voltage and current recuperation module EDPF-EM (recuperation board)
Description Statement
Input/output characteristics
Number of detection channels 8-line VAC input, 8-line AC current input
Input span PT 0~100V VAC,
CT 0~5A AC current
Output range PT 0~2.91V VAC
CT 0~2.91V VAC
Measuring precision 0.20 %@25℃, full range
Auxiliary supply ±15V
Isolation voltage >2200 Vac voltage input, > 3500 Vac current input
Service temperature -40~+75℃
Current recuperation module EDPF-EM2 (recuperation board)
Description Statement
Input/output characteristics
EDPF-NT Distributed Control System
62
Number of detection channels 16-line AC current input
Input span CT 0~5A AC current
Output range CT 0~2.91V VAC
Measuring precision 0.20 %@25℃, full range
Auxiliary supply ±15V
Isolation voltage >3500Vac
Service temperature -40~+75℃
9.2.15 ETS protection unit of steam-turbine emergency trip system
Model: EDPF-TPU
The task of ETS system (Emergency Trip System) is monitoring significant parameters of
steam-turbine, and tripping steam-turbine in emergency when exception happens in
steam-turbine. It is a significant safety system of thermal generating unit. ETS system device
needs to be provided with high reliability and high-speed capacity as well as function security and
fault security.
ETS protection unit is the most important component of EDPF-ETS. For the purpose to ensure
function security of EDPF-ETS, ETS protection unit EDPF-TPM is designed for the following
operating modes:
Redundant characteristics
It adopts completely 3-layered redundancy design, which has greatly improved the level of
equipment safety. ETS input/output signals form safe I/O channels through configurable
redundant mode like 2oo3, 2oo4 and 2oo2.
Independent characteristics
It assumes the most important redundant input signal condition of ETS system for judgment and
protection of logic operation and emergency trip output. Any fault in the controller of ETS process
control station has no impact on ETS function of emergency trip.
System features
Complete two-out-of three structure
Protective circuit realized in FPGA, independent from DPU
De-energized tripping: power-losing, voltage-losing, fault tripping
On-line maintenance: any maintenance of 3-layered redundant components, card or relay
replaceable on-line
On-line test: testing tripping circuit in operation (test logic realized in DPU)
On-line diagnostics, fault alarm
Configuring card on-line
ETS protection unit EDPF-TPU is composed of 3 EDPF-TPM modules+ 1 TPU base + 1 TPU
relay panel. Among others, TPU base provides 24 lines of DI channel terminals and 3 DB25
sockets, and TPU relay panel provides 3 DB25 sockets, 3 groups of 2oo3 redundant DC relays
and 9 independent DC relays. Each DI terminal is led to 3 TPM cards via TPU base in the
meanwhile, 3 TPM cards complete the same logic operation and output to relay panel, and to field
via 2oo3 circuit of relay finally.
ETS protection unit EDPF-TPU has 24 lines of 3-layered redundant digital input channels, among
EDPF-NT Distributed Control System
63
others, 5 lines pass the digital output trip channel avoiding act-error or act-refused decided by
2oo3, and 3 lines for alarm output.
Extend of ETS protection unit
Functionally, small steam-turbine has smaller ETS, the required digital input channels < 24 lines,
thus 1 ETS protection unit can complete all protection logic. When ETS has larger size in need of
multiple ETS protection units, each protection unit completes a part of protection logic and drives
all AST valves, and the ultimate output shall be composed of relay output concatenated.
Basic ETS configuration plan
1 cabinet + 2 groups of ETS protection units
EDPF-SD module optional
(Note 1: If DEH sends rotation speed signal to ETS system directly, it is necessary to add SD
card;
Note 2: For the purpose to realize 2oo3 redundancy, it is necessary to use 3 SD cards in the
meanwhile;
Note 3: EDPF-SD module is the module of speed measurement and steam turbine over-speed
protection.)
Available to add other types of cards like DI16, AI (note: depending on engineering design)
DI points for logic like test point and first exit point shall be led in DPU via card DI16 and
completed through soft logic.
ETS configurations under different demands
Each ETS protection unit provides 24 lines of DI channels, thus the number of DI hard-points
demanded for trip logic necessary to be completed in TPM card has decided how many ETS
protection units demanded. If DI < 20, 1 ETS protection unit can be configured; if 20 < DI < 40, 2
ETS protection units can be configured (DI channel demanded for ETS trip logic of Harbin
Turbine 600 MW steam-turbine is about 40 points, thus 2 ETS protection units are listed as the
basic configuration of ETS system); if DI > 40, 3 ETS protection units can be configured. Due to
the particularity of ETS, the highest configuration shall be 4 ETS protection units.
Multiple redundant thorough protection
2oo3 and 2oo4 logics
Signal 2oo3, as shown in panel:
信号1
信号2
信号3
与
与
与
或
Fig. 9-7 Signal 2oo3
Signal 2oo4, as shown in panel:
EDPF-NT Distributed Control System
64
信号1
信号3
信号2
与
或
信号4
或
Fig. 9-8 Signal 2oo4
Relay output 2oo3 is established with DC relays of 3 double-contacts on relay panel, as shown in
panel:
R1-1
R3-2
R2-1
R1-2
R3-1
R2-2
注:R1-2表示第1个继电器的第2对
触点,其余类推
Fig. 9-9 Relay output 2oo3
EDPF-NT Distributed Control System
65
Chapter X Fieldbus technology of EDPF-NT
10.1 Technical points of EDPF-NT fieldbus
10.1.1 DCS and fieldbus seamless integration technology
Multiple fieldbus devices can be switched in the controller of EDPF-NT system procedure control
station through standard access platform to participate in real-time control strategy, and assign
partial control functions to fieldbus devices in the meanwhile. Uniform data information
description method has ensured identical data information flow.
A transparent channel of administration information is provided in DCS controller, which enables
the fieldbus equipment management workstation to manage fieldbus devices over controller,
configure various fieldbus measuring points and control logic uniformly with DCS configuration
software and realize the function of seamless integration.
10.1.2 Multiple fieldbus protocol conversion module
Based on software and hardware technology of fieldbus protocols with independent intellectual
property, protocol conversion technology of multiple fieldbus has been researched to develop
relevant fieldbus protocol conversion module with redundant functions, and realize seamless
integration of smart instruments compatible with FF, PROFIBUS, EPA, MODBUS and HART
protocols in EDPF-NT system.
10.1.3 Comprehensive management software of fieldbus smart and non-smart devices
Based on FDT/DTM fieldbus equipment management international standard, a user can
manage multiple fieldbus smart instruments and general instruments with the same user interface
and mode.
10.2 Fieldbus access plan of EDPF-NT system
10.2.1 Standard fieldbus access platform
The latest generation of controller of EDPF-NT has integrated the Extend I/O bus (EIO)
developed by Beijing GuoDianZhishen Control Technology Co., Ltd. independently, which can
supports seamless access of third-party control systems and instruments adopting various
fieldbus protocols thoroughly.
EIO bus of industrial Ethernet frame and various fieldbus protocol conversion modules are
connected to form standard fieldbus access platform. Protocol conversion modules serve as
master station, and connect fieldbus slave station devices through the fieldbus interfaces.EIO bus
also provides transparent connection channel between fieldbus devices and upper computer
network.
Pure digital fieldbus information and conventional I/O signal are converted into EIO information
through protocol conversion module respectively. EIO network can access one or more
controllers to form a distributed control unit (DPU).
Introduction of EIO fieldbus access platform has blended two categories of I/O bus technology.
One category is multiple types of fieldbus (e.g. FF, PROFIBUS DP/PA, EPA and HART, etc.),
while the other as traditional I/O bus.
Standard fieldbus devices and I/O subsystem of IOBUS bus access EIO through protocol
adaptation module.
EDPF-NT Distributed Control System
66
EIO network can access one or more controllers to form a distributed control unit (DPU).
Any a pair of controllers on EIO bus can be assigned to form an independent logical
sub-network with access system. Multiple logical sub-network form EDPF-NT procedure
level fieldbus technical platform.
Fig. 10-1 Fieldbus access platform of EDPF-NT
10.2.2 Multiple connection schemes of EDPF-NT and third-party control systems
10.2.2.1 Fieldbus interface with traditional IOBUS bussing technique
Process controller DPU hitches EDPF-COM module through redundant IOBUS bus to provide
IOBUS procedure level fieldbus interface.
EDPF-COM module is an IOBUS bus communication interface adapter installed on
general I/O base. It supports various fieldbus communication protocol. The module is
designed with 2 insulated serial RS485 communication interfaces and a programming
interface. The default communication protocol is Modbus RTU with maximum
communication rate of 19200 BAUD. The rate of information transmission ensures digital
quantity no less than 8000 points/second, and analog quantity no less than 1000
points/second. The data handling capacity of each EDPF-COM is 1000 records.
10.2.2.2 Ethernet-based communication: communication protocol as Modbus over TCP/IP.
Third-party control system supporting Ethernet communication protocol, e.g. PLC controller, can
be hitched on EIO bus directly. If the third-party systems are more than one, network switch can
be used to construct EIO bus network. Any a pair of process controllers on EIO bus can be
assigned to form an independent logical sub-network with 1 or more third-party control system
equipment. Usually, controller establishes procedure level communication relationship as
themaster station of this sub-net with the slave stations of various third-party control systems in
the logical sub-net. Multiple logical sub-networks form EDPF-NT procedure level fieldbus
technical platform.
10.2.2.3 serial-port-based server communication: communication protocol as Modbus RTU.
EDPF-NT Distributed Control System
67
DCS acts as handover interface with third-party systems through serial-port server. One end of
serial-port server connects EIO bus through Ethernet, and another end connects third-party
control systems through RS485 or RS232 interface. Serial-port server usually has multiple
connection ports, which each port connects 1 to 16 third-party systems.It can connect multiple
third-party control systems or fieldbus instruments in the meanwhile. Any a pair of process
controllers on EIO bus can be assigned to form an independent logical sub-network with several
third-party control system equipment hitched on serial-port server to form procedure level fieldbus
communications system.
10.2.2.4 FF, BROFIBUS and HART fieldbus communication
Multiple fieldbus devices can be linked to EIO bus of DPU controller through protocol conversion
module with redundant functions to participate in real-time control strategy, and assign partial
control functions to fieldbus devices in the meanwhile.Uniform data information description
method has ensured identical data information flow.
The aforesaid four types of fieldbus device access schemes are designed with EIO function
module in process control station controller liable for fieldbus communication control and
management, and the information transmitted in one-to-one relationship with channel data of
virtual I/O modules in controller. All communication data can be processed as standard I/O data
as standard procedure level fieldbus communication plan.
10.2.2.5 Structuring high-capacity data communications gateway with EIO technology
EDPF-NT GATEWAY is a data communications gateway of large handling capacity, dedicated to
implement real-time telecommunications with high-capacity third-party control systems. This
GATEWAY can support multiple standard bus communication protocols and provide
multi-channel data transmission. Working station has built-in virtual controller, establishes
communications linkage with large-capacity third-party control system equipment through EIO
technology, converts gateway information into DCS standard data structure, and provides I/O
data processing capacity. The data handling capacity is more than 10000 points.
EDPF-NT GATEWAY is system information level data communications gateway featured as
powerful functions and high data handling capacity, suitable for intelligence transmission of hard
intensity with third-party systems.
Redundant configurations of EDPF-NT like EIO technical support fieldbus network segment, EIO
network segment, protocol transition card have ensured its high reliability and availability
sufficiently.
10.3 PROFIBUS fieldbus access schemes
Profibus fieldbus standard is matured and stable with high signaling speed, large bus capacity,
fast response speed, plenty matured products and suitable for application in thermal power
station.
Shown in the figure, EDPF-NT process control station controller (DPU) connects to PROFIBUS
protocol conversion module (NT300-PB) via EIO bus, and protocol conversion module NT300-PB
connects Profibus-DP slave stations via 4 sectional interfaces, each section available for 32
devices of slave station.Its frame diagram shall be shown as following:
EDPF-NT Distributed Control System
68
DPUEIO
PROFIBUS
PROTOCOL
CONVERTER
PORT0
PORT1
PROFIBUS
DEVICE
PROFIBUS
DEVICE
PROFIBUS
DEVICE
PROFIBUS
DEVICE
BACK PORT
BACK PORT
Fig. 10-2 Profibus protocol conversion module
10.3.1 Performance index of PROFIBUS protocol conversion module NT300-PB:
Compatible with Profibus-DP protocol standard, support all rates of Profibus-DP from 9.6 k to
12 Mbits/s
Compatible with IEC61158 PROFIBUS-DP V0 and V1 protocol standard.
Provide 4 cable ports and 2 optical ports, available with 6 sections of capability directly. More
branches expandable through bus splitter.
Each DP module can connect 120 standard slave station devices directly, and the scanning
period of each bus device is less than 1 ms @ 1.5 Mbps.
Built-in fiber optical module, convenient for remote transmission.
Communication rate from 9.6 kbps to 12 Mbps.
10.3.2 PROFIBUS fieldbus system configuration schemes
Fig. 10-3 Profibus fieldbus system configuration schemes
EDPF-NT Distributed Control System
69
10.4 EDPF-NT fieldbus equipment management software
10.4.1 Outline
EDPF-NT fieldbus function permits to use
extensive fieldbus devices. Currently, there
are more than 100 manufacturers of fieldbus
instruments and devices capable to
coordinate with EDPF-NT system, with
thousands of different types instrumental
equipment and multiple communications
protocols concerned (e.g. HART and
Profibus).
EDPF-NT must provide a simply and ease-of-use fieldbus device integration management
platform facing equipment erection and maintenance engineer. This fieldbus equipment
management platform shall be capable to integrate various fieldbus instrumental equipment
conveniently and promptly to realize transparent data access. It provides standardized work
interface and project tools for fieldbus instrument and equipment management, operations and
verification independent from device type, supplier and protocol.
EDPF-NT fieldbus equipment management software is a fieldbus device integration and
management platform based on FDT/DTM frame.
Field Device Tool (FDT) is a standard interface specification, and provides an open and
standardized integration and management platform basis independent from various smart
fieldbus instrumental equipment. The exclusive fieldbus equipment drive software or device type
management software DTM compiled by various manufacturers are organized in a single FDT
framework structure application. Each smart instrument DTM will provide all descriptive
information of this device, including configuration dialog box, parameter configuration and
Troubleshooting.
EDPF-NT fieldbus equipment management software has integrated all wired fieldbus smart
instrument drives or device type management software DTM with the help of FDT technology to
provide a standardized fieldbus equipment management platform for users, and the customer
engineer of EDPF-NT can manage all fieldbus instruments conveniently and easily.
Fieldbus equipment management software FDT (Field Device Tool) based on FDT/DTM standard
connects multiple communication protocols to a simply and ease-of-use user platform, and
integrates DTM developed by equipment manufacturer into framework applications as a software
module. FDT standardizes the data exchange mode between communication controls of field
device and control system.
FDT technology includes three elements: framework application, equipment DTM and
communication DTM/gateway DTM. Framework application is open software. Equipment DTM is
compiled and supplied by equipment developer. Communication DTM/gateway DTM software is
provided by system developer or gateway manufacturer.
EDPF-NT Distributed Control System
70
DPU01
DPU08
IP:192.168.0.8
端口号:8080
DPU31
. . . . . . . . . . . . .
. . . . . . . 卡件地址X:
Profibus协议转换
卡
卡件地址Y
地址1 地址2 地址6
地址126
. . . . . . . . . . . . . .
共126个地址
工程师站
FDT/DTM应用框架IP:192.168.0.101
端口号:8080
网络
HDLC协议
FdtCONTAINERFdtCONTAINER
My Network
COMMDTM:01
COMMDTM:08
COMMDTM:31
GATEWAYDTM: X
ProfibusDeviceDTM:
01
ProfibusDeviceDTM::
02
ProfibusDeviceDTM::
126
FileEdit View
Fig. 10-4 Block diagram of equipment management software
Based on fieldbus functional design of EDPF-NT system, EDPF-NT engineer station/fieldbus
instrument administrative station shall install FDT framework application, equipment DTM,
communication DTM and gateway DTM software. EDPF-NT process control station controller
shall install relevant communication DTM drive software. Fieldbus protocol conversion module
shall install gateway DTM drive.
For a Profibus application, the fieldbus management software on engineer station shall pass
gateway DTM and communication DTM on engineer station in turn through request sent by
PROFIBUS equipment DTM, which is transmitted to relevant process control station DPU via
EDPF-NT data highway, then sent to EIO bus via communication DTM after DPU processing,
arrives PROFIBUS protocol conversion module, and finally is sent to PROFIBUS equipment of
assigned address via gateway DTM drive software on PROFIBUS protocol conversion module.
The responses returned from equipment PROFIBUS shall also pass the following flow in turn:
PROFIBUS equipment → gateway DTM on PROFIBUS protocol transition card →
communication DTM on DPU → communication DTM on engineer station → gateway DTM →
equipment DTM, and finally displayed via equipment DTM software in fdtCONTAINER
framework.
Communication DTM hardware installed on DPU shall be liable for receiving the request on
network sent from FDT, sending to PROFIBUS protocol transition card after processing, then
sending the responses received from PROFIBUS protocol transition card to FDT after
processing.
Gateway DTM hardware drive installed on PROFIBUS protocol conversion module shall be liable
for forwarding DPU command to PROFIBUS equipment, and forwarding responses returned from
PROFIBUS equipment to DPU.
10.4.2 Primary functions of EDPF-NT fieldbus equipment management software
Scanning, recognizing equipment and
updating information
Equipment management in zones
Equipment diagnosis and alarm
monitoring
Equipment parameter configuration and
EDPF-NT Distributed Control System
71
monitoring
Verification management
History and configuration record
management
Equipment document management
Security and authority management
Addition support to general instruments
10.4.3 Examples of primary functions of EDPF-NT fieldbus equipment management
software
Fig. 10-5 Management interface of E + H temperature transmitter Fig. 10-6 Management of
ROTORK fieldbus operating mechanism
10.4.4 Configuration of EDPF-NT fieldbus equipment management software
10.4.4.1 Profibus equipment management software
Profibus equipment management software realizes multiple connection types, convenient for
users to connect and debug Profibus fieldbus instrument under various circumstances. All
connection types support real-time communication running of equipment DTM.
10.4.4.1.1 Direct connection
This mode is convenient for users to debug fieldbus instruments before all DCS configurations
completed.By this time, communication DTM of fieldbus management workstation established
connection with various Profibus protocol conversion module EDPF-PB directly through DCS
data highway. For this mode, it only needs to assign the IP address and communication port of
target Profibus EDPF-PB card with connection type as shown in figure:
PROFIBUS
EDPF-PB 卡
1 2 5
125
. . . . . . . . . . . . . .
最多126个设备
工程师站
FDT/DTM应用框架IP:192.168.0.101
端口号:8080
网络
UDP协议
FdtCONTAINERFdtCONTAINER
My Network
COMMDTM:01
COMMDTM:08
COMMDTM:31
GATEWAYDTM: X
HartDeviceDTM:01
HartDeviceDTM:02
HartDeviceDTM:08
FileEdit View
Fig. 10-7
10.4.4.1.2 DPU connection through process control station controller
This mode is compatible with EDPF-NT, except for communication DTM, and adding primary
gateway DTM. This communication DTM is connected to DPU through choosing domain No. and
operator station, send s data to Profibus EDPF-PB card via DPU forwarding, and communicates
EDPF-NT Distributed Control System
72
with real slave station, as shown in figure as follows. This mode needs not to know the IP address
of target Profibus EDPF-PB card, merely configuring point names of domain number, station
number and slave station. This mode is applicable to regular operation after configuration and
debugging completed.
DPU01
DPU08
IP:192.168.0.8
端口号:8080
DPU31
. . . . . . . . . . . . .
. . . . . . . PROFIBUS
EDPF-PB 卡
1 2 5
8
. . . . . . . . . . . . . .
最多126个设备
工程师站
FDT/DTM应用框架IP:192.168.0.101
端口号:8080
网络
UDP协议
FdtCONTAINERFdtCONTAINER
My Network
COMMDTM:01
COMMDTM:08
COMMDTM:31
GATEWAYDTM: X
HartDeviceDTM:01
HartDeviceDTM:02
HartDeviceDTM:08
FileEdit View
Fig. 10-8
10.4.4.2 HART bus equipment management software
Communication of HART bus equipment management software is compatible with EDPF-NT with
connection type as shown in figure. Request of HART equipment DTM on fieldbus administrative
station passes gateway DTM and communication DTM in turn, then is sent to communication
DTM driver of process control station controller DPU via EDPF-NT data highway. DPU controller
adopts IOBUS bus of HDLC protocol to send this request to HART protocol transition card, and
finally to HART card of assigned channel via HART protocol transition card. The responses
returned from HART card shall also pass the following flow in turn: HART card → HART protocol
transition card → DPU → communication DTM of engineer → gateway DTM → equipment DTM,
and finally displayed in fdtCONTAINER framework.
DPU01
DPU08
IP:192.168.0.8
端口号:8080
DPU31
. . . . . . . . . . . . .
. . . . . . . 卡件地址X:
HART协议转换卡
卡件地址Y
通道1 通道2 通道5
通道8
. . . . . . . . . . . . . .
共8个通道
工程师站
FDT/DTM应用框架IP:192.168.0.101
端口号:8080
网络
HDLC协议
FdtCONTAINERFdtCONTAINER
My Network
COMMDTM:01
COMMDTM:08
COMMDTM:31
GATEWAYDTM: X
HartDeviceDTM:01
HartDeviceDTM:02
HartDeviceDTM:08
FileEdit View
Fig. 10-9
EDPF-NT Distributed Control System
73
After configurations of HART communication DTM and gateway DTM completed, add relevant
equipment DTM, and capable to communicate with HART equipment in real time.
10.5 Summary
Plenty application practices have indicated that EDPF-NT has been exactly provided with the
capability of full-open fieldbus seamless connection.
EIO technology has provided standard platform of fieldbus access.
PROFIBUS protocol adaptation module has provided well-behaved PROFIBUS procedural
interface.
New I/O modules have provided HART bus protocol support.
Fieldbus equipment management software based on FDT/DTM standard has provided the
function of fieldbus equipment management.
Fieldbus technology is growing matured in technical application specifications in large-scale
thermal power units, and the advanced fieldbus technology of EDPF-NT will play a vital role in
this new technological revolution.
EDPF-NT Distributed Control System
74
Chapter XI Other principal hardware units of EDPF-NT
11.1 Industrial network switch
Information isolation and interconnection among EDPF-NT domains is realized with the advanced
and matured network information control list (ACL) technology. The concept of ACL (access
control list) is to use packet filtering technique, read information in packet heads of layer 3 and
layer 4, e.g. source address, destination address, source port and destination port, filter packets
based on the predefined rules, and realize the purpose of access control.
Nodes in DCS system network can be distinguished into resource node and control node in
general, among others, resource node provides data and receives commands, and control node
accesses data of resource node and sends commands. The function of ACL is to protect resource
node on one hand, so as to stop illegal access to resource node, and restrict the access rights of
certain control node on the other hand.
Generally speaking, ACL technology can permit the information of utility system DCS and various
unit DCS communicated, and isolating communication of different unit DCS effectively in the
meanwhile.
Fig. 11-1 Comparison of topological diagrams of network communication before and after
technology enabled (laboratory data)
Note: Right side of Fig. (1) is the effect after using ACL technology, which has isolated all data of
domain 2# effectively.
EDPF-NT system data communication adopts network multicasting technology, i.e. Internet
Group Management Protocol (IGMP). Currently, IGMP has three main versions: IGMPv1
(RFC1112), IGMPv2 (RFC2236), IGMPv3 (RFC3376). IGMP multicasting membership
management system is designed against layer 3, which realizes control over multicasting
message forwarding on layer 3 router. For the purpose to adapt to the multicasting application of
layer 2 switching equipment, IGMP-Snooping monitoring system is introduced. Because
EDPF-NT network has no layer 3 equipment, i.e. router (slow data forwarding of router fails to
satisfy the requirement of instantaneity), layer 2 switch is necessary to support IGMP protocol
separately. However, various switch manufacturers have slight difference in supporting the
realization method in this multicasting environment without router. When the developing
laboratory of Beijing GuoDianZhishen Control Technology Co., Ltd. tested, it has been found that
certain well-known imported brand network switch run a period of time and multicasting
EDPF-NT Distributed Control System
75
forwarding failed.In case of without functionality test of interconnection and intercommunication in
laboratory or long-term stability and reliability demonstration at project site, adopting these
imported network switches without due consideration may appear unpredictable problem of
compatibility, result in unstability of DCS system, and then impact on reliable operation of units.
Fig. 11-2 Comparison of load diagrams of network communication before and after IGMP
enabled (laboratory data)
Note: Right side is the effect after using IGMP technology, which has reduced network load
effectively.
The network switches recommended by Beijing GuoDianZhishen Control Technology Co., Ltd.
have undergone long-term rigorous network system test, and the product technology of these
network switches has been proved with high maturity, good reliability, and complete compatibility
with the new network technologies to be used in EDPF-NT system.
EDPF-NT works at industrial field for long time, thus it has special requirements on type selection
of network switch:
Choose industrial network switch.
Network switch adopts double 24 VDC power supplies, free of mechanical cooling fan,
communication port available for modular configurations, fair tolerance to adverse working
environments, e.g. high-temperature, dust, moisture and electromagnetic interference. Rack
or shelf mountable.
Network switch has function of network administration, and supports IGMP multicasting and
ACL access control list. IGMP multicasting and ACL access control list technologies are
important supporting technologies for realization of EDPF-NT multiple domain network
management function.
Network switch has high price performance with plenty achievements in industrial
application.
11.2 EDPF-NT exclusive power supply quick switch device
EDPF-NT system power supply cabinet is equipped with QPS double-circuit AC undisturbed
automatic switch device designed and produced by this Company independently. It is mainly
aimed at industrial automatic system application with high requirements and reliable supply of
single-phase AC220V and load-carrying capacity 8-20 A. QPS series of redundant power switch
device adopt all-digital AC sampling and moving window detection technology, which can monitor
the poled primary/standby AC power supplies in real time. When two ways of input power
EDPF-NT Distributed Control System
76
supplies are both in normal status, the output is connected to the main power automatically.
When the main power occurs power-fail or the voltage is lower than 200 V or higher than 250 V or
the voltage of stand-by power is higher than 200 V, it will be switched to the stand-by power
automatically under action of internal control. The switching time shall be less than 10 ms. After
the primary power supply resumes power supply, and the voltage is higher than 210 V, it can
switch back to the primary power supply automatically and quickly. This device is also designed
with two ways of AC power supply monitoring windows to monitor the AC voltages visually.
QPS redundant power switch device is designed exactly in concordance with strict industrial
environment. The control kernel adopts single-chip (MCU) control device, which ensures the
working process free from contingencies with particular hardware logic, e.g. system crash or
program runaway. And this device can resist 4 KV pulse train and surge impact, 8 KV static
discharge (15 KV air discharge) with interference-free feature reaching international standard
IEC61000-2004-level 4, and run in various bad industrial field environments for long time.
Fig. 11-3 QPS redundant power supply quick switch device
The most imported universal power supply switching devices are applicable to significant
commercial and industrial power supply instead of used for computer-control system equipment
exclusively, thus there is the problem of anti-interference ability and index matching, impossible to
ensure complete matching with EDPF-NT.
Beijing GuoDianZhishen Control Technology Co., Ltd. promises that all indexes of QPS
double-circuit AC undisturbed automatic switching device have satisfied and surpassed the
requirements of industrial automation system technology, and provides total quality assurance.
Technical parameters of QPS series of redundant power supply quick switch device
QPS series of redundant power supply quick switch device
Parameter value:
Max. rated voltage 250VAC
Action voltage Action voltage: < 200 VAC or > 250 VAC
Recovery voltage >210VAC
Switching time 5ms--13ms, typical 10ms
Including, testing time 2ms--6ms
Including, action time 3ms--8ms
Voltage measurement
precision 2%
Recovery delayed time 100ms
EDPF-NT Distributed Control System
77
Interface parameters:
Input AC220VAC:AC1 (primary), AC2 (standby)
Output AC220VAC: OUT1, OUT2, OUT3, OUT4, OUT5
Alarm ALARM (dry contact 120mA/350V)
Control extending port CTRL-OUT (AC220VAC/120mA)
Insulating resistance >1 G Ω (1000 V)
Anti-interference level Class 3
Static discharge interference
immunity 6000 V Class 3
Electrical fast transient pulse
train interference immunity 2000 V Class 3
Surge interference immunity 2000 V Class 3
Pulsed magnet field
interference immunity 1000A/M
11.3 Exclusive DC power supply
Exclusive DC power supply is used to provide redundant DC supply for controller, smart I/O
modules, field transmitter and switching value query at EDPF-NT process control station. This
power supply receives two ways of independent 220 VAC power inputs, provides two ways of
independent 24 VDC/48VDC power supplies, and has functions of power failure indication and
power supply short-circuit protection. Among others, 48 VDC power supply os used for switching
value status query exclusively.
Fig. 11-4 Legend of exclusive DC power supply
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Chapter XII EDPF-NT type DEH system
Beijing GuoDianZhishen Control Technology Co., Ltd. is engaged in design and production of
sophisticated and first-class digital steam-turbine electrohyraulic control system compatible with
function requirements of application for a long time. The Company has an experienced team of
design and debugging. Various digital steam-turbine electrohyraulic control systems designed
and produced (DEH/ETS, MEH/METS) have found wide use. Our DEH/MEH has outstanding
achievements of hundreds of project applications not only as a functional subsystem of DCS but
also as exclusive matching product in large-scale steam-turbine station.
12.1 DCS-integrated DEH
12.1.1 Configurations of DEH electronics and outline
EDPF-DEH is one of exclusive subsystems in EDPF-NT, based on the powerful supporting
environment of EDPF-NT, adopting the software, hardware and communication system identical
to EDPF-NT process control station, adding DEH-dedicated software and hardware, configuring
the system processing cyclic into 20 ms fast processing mode based on special demand of DEH,
and shape a unique EDPF-DEH electric control system.
Adopt redundant controller identical to EDPF-NT process station, fast switching speed of
primary/standby controllers, safe and reliable, maximum control cycle of system less than 30
ms, higher control precision.
MMI and configuration software identical to EDPF-NT exactly, easy-to-learn, ease-of-use,
and ease-of-maintenance.
Real-time database exactly integrated with EDPF-NT.
Data communication system identical to EDPF-NT to ensure non-delay of data transmission,
unnecessary to provide gateway, realizing integrated distributed control system of unit in
deed.
Function integrated, smart speed measurement and OPC function module enabling speed
measurement cyclic and OPC action time as short as 20 ms and 2 ms respectively. Smart
servo shall power amplifier module providing more compact and reliable system.
All application operations of digital steam-turbine electrohyraulic control system (DEH/MEH)
are realized on EDPF-NT operator station to control operation of steam turbine through
window panels on computer and mouse, which has canceled traditional operation panel of
steam turbine to provide merits of flexible operations, friendly MMI and rich monitoring
information. The hardware is safe and reliable, easy-to-configuration and convenient for
maintenance.
12.2 Technical requirements of EDPF-DEH control system
Range of speed control 50-3500 rpm. Under rated condition, the speed fluctuation range
caused by rotary speed control shall be not larger than 0.1 % of the rated speed.
Load control range 0-110 %. Under rated condition, the power fluctuation range caused by
power control shall be not larger than 0.5 % of the rated power.
Rotation speed diversity factor continuously adjustable 3-6 %.
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System stagnant rate ≤ 0.06 %.
Full-load shedding rotation speed overshooting ≤ 7 %.
Full travel quick closure time of oil-driven machine ≤ 0.15 second.
System control turnaround time ≤ 50 ms.
DEH even continuous failure-free operation time > 8000 hours, electric control device >
20000 hours.
System availability factor > 99.9 %.
12.3 EDPF-NT system speed measurement card
12.3.1 EDPF-SD steam turbine speed measurement and over-speed protection card
1 SD card accesses 3 lines of rotation speed signals in the meanwhile. System requires 2
redundant SD cards, while 3 lines of rotation speed signals and 3 lines of oil switching signals
access 2 SD cards in the meanwhile via transferring terminal row. For the purpose to avoid signal
interference from transferring terminal row to connectors of SD card, the signal cable from
transferring terminal row to SD card shall be twisted pair. Wiring of oil switch signals from
transferring terminal row to SD card shall be ensured with consistence.
SD cards are used, and the selection logic of 3 lines of rotation speed signals shall be completed
on SD card. The rotation speed chosen by two SD cards shall be subject to select-high in
controller as the final rpm value. 3 lines of oil switch signals shall be subject to 2-out-of-3 logical
decision on SD cards before sending effective oil switch signals. OPC and AST operation signals
of two SD cards are outputted as final action after logic decision.
EDPF-SD card has protective function featured as accurate and fast response and output.
12.3.2 EDPF-SD1 card
1 SD1 card accesses 1 line of rotation speed signal. The system is usually equipped with 3 SD
cards, while each SD1 card accesses 1 line of rotation speed signal and 1 line of oil switch signal.
SD1 cards are used. 3-line rotation speed signal selection logic is completed with 3 algorithm in
controller. OPC and AST operation signals of 3 SD1 cards are finally outputed after 2-out-of-3
logical decision with intermediate relay.
12.3.3 Relationship about oil switch and OPC
For OPC function of EDPF-SD speed measurement and steam turbine protection card, if acting
when oil switch turning from closed to disconnected, it is necessary to consider the unit load at
moment of stepout. Specifically, there is an internal point of LDA on speed measurement card
(sent to speed measurement card from DPU controller). When the status of this point is 1, oil
switch turns from closed to disconnected, and speed measurement card OPC will act. Currently:
the specific method shall be as follows: conduct upper bound judgment on unit load (limitation as
15%~20%of rated load), and judgment result outputted LDA signal to each speed measurement
card through TIME OFF algorithm (time as 2S). For speed measurement card before 2004, when
oil switch turns from closed to disconnected, OPC acts immediately instead of confined by load
condition.
The method to inspect the relationship between oil switch and OPC in DEH system under
operation if limited by load condition shall be as follows: inspect system if having generated LDA
point to speed measurement card, and if existing relevant logic; conduct static test under halt
condition for further verification.
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12.3.4 About signal "rotation speed configuration larger than constant"
Speed measurement card needs the controller to send a signal "rotation speed configuration
larger than constant". When "rotation speed configuration larger than constant" is false (i.e.
rotation speed configuration lower than constant), speed measurement card will not conduct
judgment on lower bound limitation or change rate overbound when judging the quality of all lines
of rotation speed signals. The constant which in "rotation speed configuration larger than
constant" is generally set about 1000rpm. Speed setting refers to the speed setting value that will
participate in speed adjustment PID operation eventually.
12.4 About EDPF-NT system valve control card
12.4.1 VC card output signal type
Currently, there are 3 types of VC card output signals of EDPF system:
-10V~+10V: mainly used for fire-resistant oil DEH and MEH systems.
4~20mA and -10mA~+10 mA: mainly used for turbine oil DEH and MEH systems. Attention
shall be paid to verify the control signal type of electro-hydraulic converter of different
manufacturers. Currently, there are certain products using AO card to output 4~20 mA for
control.
12.4.2 VC card LVDT type
Currently, VC card LVDT type of EDPF system mainly includes sensor signal of three-wire system
and transmitter signal of 4~20 mA system in double-circuit. It can also provide VC card using sensor
signal of six-wire system in single circuit.
12.5 1000 MW ultra-super-critical steam-turbine electrohyraulic control system
1000 MW ultra-super-critical steam-turbine electrohyraulic control system (DEH) is the commanding
point of control system technology generally accepted in industry of thermal control field. Because the
requirements of control target are extremely rigorous, it is always supplied by foreign manufacturers.
This Company cooperates with Shanghai Turbine Station in development of independent 1000 MW
ultra-super-critical turbine DEH. Currently, the development of system platform has be completed, the
applications are being configured. The main technical parameters shall be:
Speed measurement card of Hall probe to realize precise zero-speed monitoring;
Speed measurement cycle of speed measurement card shortened to 5 mS, having improved the
capability of quick-response to speed change;
Redundant configuration of control valve servo-card, standby card output tracking,
primary/standby cards output driving corresponding servo-circles respectively, so as to ensure
output co-rotating and undisturbed switching;
Double I/O bus high/low speed configurations to ensure the response cycle of rotary speed
control less than 40 mS.
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Chapter XIII DCS monitoring software based on WEB
technology
When coordinating with DCS, Web monitoring system acts as enhancement module of DCS to
provide Web interface for DCS so as to satisfy the demand of various remote accesses.
DCS monitoring software based on WEB technology is formed as follows:
Web server, a computer system supporting operation of Web monitoring and control system.
Multiple CPU frameworks, including X86, ARM and Power, using Windows/Linu operation
system.
Web client-end, without any restriction on CPU framework or operation system, only if capable to
run browser for access. The screen size and resolution of different hardware units are different.
For the purpose to reach nice experience of interaction, it is necessary to design different UI
schemes based on specific circumstances.
Mobile APP, Web monitoring system can be compatible for access of mobile APP like
mobile-phone.
Database, to provide simple underlying database and share real-time historical database with
DCS.
DCS monitoring software based on WEB technology has advantages as follows:
Cross-platform. Monitoring interface developed with Web technology can run in any environment
capable to run browser, including various smart devices like IPC, laptop, tablet PC and
mobile-phone. There is no limitation to operating system environment, which may be
Windows/Unix/Linux/iOS/Android.
Advanced technology. Web technology is one of the computer display technologies with the
fastest development in the last 10 years.
Ease-to-deployment and management. In Web technology, all programs in need of management
and deployment are concentrated on server, can be updated and maintained easily.
Good expandability. Web technology is provided with nice elasticity inherently, easy of expansion,
convenient for later maintenance and upgrading; also can be integrated with other Web systems.
DCS monitoring software based on WEB technology has primary functions as follows:
Monitor production processes in working environments with browser installed (computer, PAD,
mobile-phone), including status of equipment and various production parameters.
Send commands to operating mechanism, implement authorization control and intervention of
production process.
When the system occurs abnormal situation, it will issue alarm to remind users for prompt
attention.
Query the history conditions of production process, so as to facilitate failure handling and
problem analysis.
Query records of user operation.
Complete auxiliary tasks like reporting and drawing tendency chart.
Operation authority management of operators, who can not implement operations other than
authority.
Web functional function block of EDPF-NT mainly has two application scenarios:
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Support development of wind power controller to shape wind power monitoring software.
Channel intelligence test system of DCS module.
Routine I/O channel test needs at least two technicians holding interphones at I/O terminal
cabinets of DCS engineer station and process station respectively. Observe channel quality on
display of engineer station through loading measuring signal.
New testing tool merely needs one technicians holding Pad or mobile-phone at I/O terminal
cabinet of process station to observe channel quality through Web page.
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Chapter XIV EDPF-CP Industrial Automation System
EDPF-CP is a new industrial automation system developed by Beijing GuoDianZhishen Control
Technology Co., Ltd. In addition to inheriting the superior characteristics of EDPF-NT system
thoroughly, this system also has universal function and capacity of PLC. The characteristics shall
be as follows:
New industrialized design, small size, aesthetic appearance. Flexible installation method can
support support frame horizontal installation and terminal module integrated vertical installation in
the meanwhile.
Twin-engine controller pioneering at home and abroad, provided with merits of PLC and DCS in
the meanwhile, supporting various application environments of industrial automation
comprehensively.
Support SAMA chart control configuration of DCS and 5 standard programming languages of
61131-3.
Twin engine controller kernel software compatible for PLC and DCS.
EDPF-CP built-in PLC and DCS dual-control engine, integrating the merits of digital quantity of
PLC controller with good instantaneity, high reliability, simplicity and ease-of-use as well as
features of DCS analog quantity with powerful processing capacity, strong network function and
rich control algorithms.
As compared with each other, PLC and DCS controllers have their own relative merits
respectively. Comparison shall be as follows:
Features of PLC controller shall be as follows:
Multitask sequential scheduling, high reliability, particularly suitable for sequential control.
Support 5 programming languages of IEC61131-3 standard.
Abundant fieldbus support, good network openness.
Slave station mode, simple algorithm, difficult to undertake application of massive
coordination control occasions, suitable for device control application.
Features of DCS controller shall be as follows:
Multitasks scheduled as per priority occupation, with powerful processing capacity of
modulating. Suitable for implementation of complicated coordination control.
Support graphic control configuration mode, e.g. SAMA standard.
Strong network function, convenient to form massive control system.
Powerful control algorithm library.
The built-in PLC and DCS dual control engines of EDPF-CP system can run separately, parallelly,
and in coordination. It has greatly extended the capacity and application domain of control
system.
Single engine running mode: when only PLC or DCS control engine is running, the controller
becomes a programmable controller or DCS process control station. It can adapt to different
demands on application.
Twin engine parallel running mode: PLC function can complete sequence control more easily,
DCS function can complete complex control adjustment more smoothly, and both engines share
real-time data through internal mechanism.
EDPF-CP twin-engine controller running mode can still be distinguished into twin-engine
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coordination mode dominated by PLC and twin-engine coordination mode dominated by DCS.
Twin-engine coordination mode dominated by PLC means that: to make use of the features of
PLC engine, e.g. powerful functions of sequence control and fast calculating speed to control the
controlled devices, and make use of the powerful network and algorithm library of DCS engine to
complete complex data analysis, statistics and calculation, and blend all information to DCS
system through network.
Twin-engine coordination mode dominated by DCS means that: a user can use PLC as private
process algorithm library to expand the control function of DCS further and realize the double
convenience of process logical security and debugging.
Fig. 14-1 EDPF-CP system diagram
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Chapter XV Typical achievements of EDPF-NT
Up to December of 2016, EDPF-NT series of Dstributed Control System of Beijing
GuoDianZhishen Control Technology Co., Ltd. had outstanding achievements of 1950 sets,
including:
Applied to 1000 MW and ultra-super-critical thermal
power units 22 sets
Applied to 600 MW and super-critical thermal power
units 33sets
Applied to 300 MW thermal power units 202 sets
Applied to 300 MW or less thermal power units 250 sets
Applied to nuclear power concerned 7 sets
Applied to hydro power station control 19 sets
Applied to auxiliary shop control and municipal heating
system control 295 sets
Others 1122 sets
Massive application performance has indicated that EDPF-NT system of Beijing GuoDianZhishen
Control Technology Co., Ltd. has been capable to be applied to any heavy-duty generating unit.
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Among numerous achievements, EDPF-NT system has been applied to various large units and
the first unit and first set in China and the world for many times as follows:
15.1 2×1000MW ultra-super-critical units of Guodian Jianbi Power Station
This project was the domestic DCS system applied to 1000 MW ultra-super-critical unit for the
first time.
Primary functions realized by DCS in this project include: data acquisition system (DAS),
modulating control system (MCS), furnace security supervisory system (FSSS), sequence control
system (SCS) and electric control system (ECS). The scope of control and monitoring includes
the thermal production system of boiler, steam-turbine and auxiliaries, transform bank and station
supply system, circulating water system, by-path system, boiler soot blower system, denitration
system, firing system, cooling water circuit, boiler starting system, desulfurization system.
Host unit side is equipped with 44 pairs of DPUs, 6 pairs shared by host, 2 pairs for
desulfurization units, 3 pairs for desulphation utilities, thus two units plus the common and
desulphation have 101 pairs of DPUs.
Size of real I/O points: host unit 11231 points, host shared 1711 points, desulfurization unit 831
points, desulphation shared 1630 points, thus two units plus shared system have about 24000
points in total.In addition, unit side has 746 intelligent front end I/O points (communication points).
15.2 2×1000MW ultra-super-critical units of Guohua Xuzhou Power Station
Primary functions realized in this project include: data acquisition system (DAS), modulating
control system (MCS), furnace security supervisory system (FSSS), sequence control system
(SCS) and electric control system (ECS).The scope of control and monitoring includes the
thermal production system of boiler, steam-turbine and auxiliaries, transform bank and station
supply system, circulating water system, by-path system, boiler soot blower system, denitration
system, firing system, cooling water circuit, boiler starting system, desulfurization system.
DPU allocation: 40 pairs of DPUs for host unit side, 4 pairs shared by host, 3 pairs for
desulfurization units, 7 pairs for desulfurization utilities, thus 2 units plus the common and
desulphation have 97 pairs of DPUs.
Size of real I/O points: host unit 9025 points, host shared 968 points, desulfurization unit 1234
points, desulphation shared 2180 points, thus 2 units plus shared system have about 24000
points in total. In addition, unit side has 1090 intelligent front end I/O points (communication
points). Among others, unit side denitration system and water circulating pump system have
remote I/O cabinets, fuel pump house of utility system has remote I/O cabinet, and desulphation
utility system also has 6 remote I/O cabinets.
15.3 2×1000MW ultra-super-critical units of Guodian Hanchuan Power Station
Primary functions realized by DCS in this project include: data acquisition system (DAS),
modulating control system (MCS), furnace security supervisory system (FSSS), sequence control
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system (SCS) and electric control system (ECS).The scope of control and monitoring includes the
thermal production system of boiler, steam-turbine and auxiliaries, transform bank and station
supply system, circulating water system, by-path system, boiler soot blower system, denitration
system, firing system, cooling water circuit, boiler starting system, desulfurization system.
DPU allocation: 44 pairs of DPUs for host unit side, 4 pairs shared by host, 4 pairs for
desulfurization units, 3 pairs for desulphation utilities, thus 2 units plus the common and
desulphation have 103 pairs of DPUs.
Size of real I/O points: host unit 9293 points, host shared 353 points, desulfurization unit 1190
points, desulfurization shared 1075 points, thus 2 units plus shared system have about 23000
points in total.
15.4 2×1000MW ultra-super-critical secondary reheat units of Guodian Taizhou
Power Station
Primary functions realized by DCS in this project include: data acquisition system (DAS),
modulating control system (MCS), furnace security supervisory system (FSSS), sequence control
system (SCS) and electric control system (ECS). The scope of control and monitoring includes
the thermal production system of boiler, steam-turbine and auxiliaries, transform bank and station
supply system, circulating water system, by-path system, boiler soot blower system, denitration
system, firing system, cooling water circuit, boiler starting system, desulfurization system.
DPU allocation: 54 pairs of DPUs for host unit side, 4 pairs shared by host, thus 2 units plus the
common and desulfurization have 123 pairs of DPUs.
Size of real I/O points: host unit 13168 points, host shared 631 points, thus two units plus shared
system have about 26967 points in total.
This project had technological break-through in aspects including coordination control, climatic
control, three-level by-pass overall control, water supply overall control, fuel auto overall control,
and unit auto start/stop control (APS).
15.5 600 MW super-critical cycle fluidized-bed generating units of Sichuan
Baima Power Station
---The only one 600 MW super-critical cycle fluidized-bed generating unit in the world
Primary functions realized by DCS in this project include: data acquisition system (DAS),
modulating control system (MCS), furnace security supervisory system (FSSS), sequence control
system (SCS) and electric control system (ECS).The scope of control and monitoring includes the
thermal production system of boiler, steam-turbine and auxiliaries, transform bank and station
supply system, circulating water system, by-path system, denitration system, firing system,
cooling water circuit, boiler starting system, desulfurization system.
DPU allocation: 25 pairs of DPUs for host unit side, 5 pairs for remote system, thus 2 units plus
the common and desulphation have 30 pairs of DPUs.
Size of real I/O points: host unit 6816 points, host shared 1397 points, thus 2 units plus shared
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system have about 8213 points in total.
Because this project had higher difficulty, Beijing GuoDian Zhishen Control Technology Co., Ltd
developed a complete set of control policy optimistic algorithm applicable to super-critical cycle
fluidized-bed unit. Among others, boiler combustion heat calculation, SO2 prediction subtraction
control, self-balancing water supply command, sliding variable pure lag estimator used for
main-steam pressure-control, non-linearity double governor (PID + PD), and boiler heat retaining
compensated acceleration module are original technologies.
15.6 2×660MW ultra-super-critical units of Guodian Bulian Power Station
---Single row heavy-duty generating units as important auxiliaries of boiler
Primary functions realized by DCS in this project include: data acquisition system (DAS),
modulating control system (MCS), furnace security supervisory system (FSSS), sequence control
system (SCS) and electric control system (ECS). The scope of control and monitoring includes
the thermal production system of boiler, steam-turbine and auxiliaries, transform bank and station
supply system, circulating water system, by-path system, denitration system, firing system,
cooling water circuit, boiler starting system, desulfurization system.
DPU allocation: 35 pairs of DPUs for DCS configurations of unit station, 6 pairs for utility system.
Including 85 pairs of DPUs for desulfurization and denitrification. 12 pairs of DPUs for auxiliary
water system, 3 pairs of DPUs for coal conveying system, 5 pairs of DPUs for ash removal
system, and 1 pair of DPU for boiler starting.
Size of real I/O points: host unit 10470 points, host shared 1453 points, thus two units plus shared
system have about 22393 points in total.Auxiliary water system 2490 points (including starting
boiler), coal conveying system 984 points, ash removal system 2656 points, and auxiliary network
6130 points in total.
This project adopts full ancillary single row arrangement, and DCS has ensured stable and safe
opration of units with optimized allocation of controllers and redundant cards.
Tel:+86-10-52615188 Hot line:+86-400 008 6060
Fax:+86-10-52615176 Web:www.gdzhishen.com
Mail: [email protected]