Advanced Control Systems for ESP 3
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Transcript of Advanced Control Systems for ESP 3
![Page 1: Advanced Control Systems for ESP 3](https://reader031.fdocuments.us/reader031/viewer/2022012303/546f0f45b4af9f1c3c8b4573/html5/thumbnails/1.jpg)
Presentation on Presentation on Advancements in ESP Control Advancements in ESP Control
SystemSystem
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04/08/23 Copyright 2006 BHEL, Ranipet 2
R&D CenterR&D Center
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Evolution of ESP controllers Evolution of ESP controllers in BHELin BHEL
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04/08/23 Copyright 2006 BHEL, Ranipet 4
ESP HVR CONTROL
ANALOG CONTROLLER AICE - C
RAPPING CONTROL
SYNCHRONOUS PROGRAMMER
AUTORAPPER
P BASED RAPPER CONTROLLER
MANUAL CONTROL COMPUTER CONTROLLEDPRECIPITATOR OPERATION
ESP CONTROL
BAPCON
RAPCON
IOS
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High Voltage Rectifier High Voltage Rectifier ControllersControllers
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04/08/23 Copyright 2006 BHEL, Ranipet 6
Basic factors affecting ESP performanceBasic factors affecting ESP performance
Properties of Flyash - Particle size distribution -small particles are difficult to collect - surface area affects visibility, space charge
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04/08/23 Copyright 2006 BHEL, Ranipet 7
+
+
+
+
+
+BACK CORONA
qs
x i
+ ++ +
-------
EP Qs E p
F = Qs . Eav Ep . Eav Vp . Vav
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04/08/23 Copyright 2006 BHEL, Ranipet 8
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04/08/23 Copyright 2006 BHEL, Ranipet 9
Modified Intermittent ChargingModified Intermittent Charging
Increases the base voltage More suited for high charge ratio operation suitable for high resistivity dust
Outlet emission Power consumption (mg/Nm^3) (kW)
Conventional charging 351 300
Intermittent charging 127 57
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04/08/23 Copyright 2006 BHEL, Ranipet 10
Energy SavingEnergy Saving
Reduction in energy costs due to modified intermittent charging
210 MW ESPReduction in power : 243 kWAt 2 Rs./kWH and 65% duty, yearly saving : Rs. 27.7 Lakhs
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04/08/23 Copyright 2006 BHEL, Ranipet 11
BAPCONBAPCON
BHEL’s Advanced Precipitator CONtroller (BAPCON)
Highly reliable Displays in % Local & Remote
operation CR mode Warning & TRIP Alarms
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04/08/23 Copyright 2006 BHEL, Ranipet 12
Schematics of BAPCONSchematics of BAPCON
Feedback control system IP65 packing
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04/08/23 Copyright 2006 BHEL, Ranipet 13
BAPCONBAPCON
• Intermittent charging, requirement of wide charge ratio (CR) range of 1:159.
• Optimiser logic for C.R, avoids tedious manual tunning.
• Base charging, increases base voltage.• Peak & valley KV measurement : Diagnostic &
tunning facilitated.
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04/08/23 Copyright 2006 BHEL, Ranipet 14
VARIOUS DISPLAYS IN BAPCONVARIOUS DISPLAYS IN BAPCON
- Precipitator currentE Precipitator voltage H Sparks per minuteO Im limit1 Is limit2 S control3 Time control4 Stabilization time5 U.V. Limit6 C.R.7 Pulse current limit8 Repeat time9 Address Peak & valley voltageP Base chargeL Base charge current
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04/08/23 Copyright 2006 BHEL, Ranipet 15
ALARMS IN BAPCONALARMS IN BAPCONo TRIP ALARMS:
o E1 - Safety chain broken.o E2 - Eprom faulty.o E3 - Power supply failure.o E4 - Over voltageo E5 - Ash level very high (for 10 min.)o E6 - T/R temp very high / TH. Ovld.o E7 - Bucholtz bottom float.
o WARNING ALARMS:o T/R temp high.o Bucholtz top float.o Ash level high.o Under voltage.
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04/08/23 Copyright 2006 BHEL, Ranipet 16
SIGNALCONDNG
AMP.
PEAK &VALLEYDETCTR.
SIGNAL CONDNG
AMP.
SPARKDETECTOR
ANALOGTO
DIGITALCONVTR.ADC 0816)
PROGRAM(EPROM)2732 / 2764
PROCESSOR8085
OUTPUTRELAYS
PORT 1I/O
8155
SYNCH.SIGNAL
PORT 2I/O
8155
SERIALCOM.(8251)
KEYBOARD
ALARMS
FIRINGSGNL.O/P
ADDRESSSET
SPARKCOUNTER
INDICATI-NG LEDs
WATCHDOG DISPLAY
CURRET
SIGNAL
FROMTR
VOLTAGE
SIGNAL
FROMTR
SET POINT
POT. METERS.
BAPCON - DETAILED BLOCK DIAGRAM
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04/08/23 Copyright 2006 BHEL, Ranipet 17
BAPCONplusBAPCONplus
Engineering Unit display Designed for 660MW
application VFD display Local & Remote
operation CR mode Base Charge mode Warning & TRIP Alarms
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04/08/23 Copyright 2006 BHEL, Ranipet 18
BAPCON-IIBAPCON-II
Single board design Fewer components,
Higher reliability RS-485 bus based high-
speed network Remote operation Concealed in HVR panel In-built rapping
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04/08/23 Copyright 2006 BHEL, Ranipet 19
BAPCONsigmaBAPCONsigma
Primary parameters measurement
Power Measurement Open Standard
MultiMaster Network Peer to Peer
communication Spark & Arc detection and
suppression Single card design Concealed in HVR panel In-built rapping
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Rapping SystemRapping System
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RAPCONRAPCON
Highly Reliable platform Standalone operation Local & Remote mode
operation Real Time Clock based
motor operation Advanced algorithms
support Standby mode
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ADVANCED FEATURES OF RAPCONADVANCED FEATURES OF RAPCON
Error checking for the motors. Setting of rapper timings. Setting of real time. Auto on/off selection. Manual on/off selection. Password protection. Setting of program set no. Reading of rapper times. Reading of real time. Reading of program set no. Reading of rapcon address. Reset alarm. Stan by mode selection. Communication with IOS-PC Rapping factor selection - [IOS]
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04/08/23 Copyright 2006 BHEL, Ranipet 23
PARAMETERS IN RAPCON CONTROLLED BY IOS - P.C.PARAMETERS IN RAPCON CONTROLLED BY IOS - P.C.
Rapping factor. Program set no. Auto on/off. Manual on/off. Set real time. Set rapping time. Get rapping time. Reset alarm.
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04/08/23 Copyright 2006 BHEL, Ranipet 24
COMMAND TO RAPCONCOMMAND TO RAPCON Force stand alone / standby Auto ON / OFF for all motors Manual ON / OFF for all motors Program set selection 1 - 64 Time factor 0 - 25.5 Alarm reset
REPLY FROM RAPCONREPLY FROM RAPCON Remote local Auto ON / OFF status Manual ON / OFF status Program set Time factor Alarm status Motor status Motor status 30 sec. In advance Next on status
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CPU CARD( 8085 )
DISPLAY &
K.B. CARD
DATA COMMN.CARD
INPUT BUFFER
CARD
ISOLATOR
P.S.CARD
REPLY CARD
BLOCK DIAGRAM OF RAPCON BLOCK DIAGRAM OF RAPCON HARDWAREHARDWARE
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04/08/23 Copyright 2006 BHEL, Ranipet 26
BLOCK DIAGRAM OF CPU CARD OF RAPCONBLOCK DIAGRAM OF CPU CARD OF RAPCON
8254TIMER
8259PIC
8251USART
8251USART
8085
MICRO
PROCESSOR
WATCH
DOG
CIRCUIT
EPROM27128
EPROM27128
8255PPI
8255PPI
4 3 2 1
RAM6264
FEEDBACK FROM
MOTOR CONTACTS
TO MOTOR CONTACTS
DIP
SWITCH
6.144 MHz
TIMER 0TIMER 1TIMER2
IR 0IR 1
IR 7
TX
RX
TX
RX
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BLOCK DIAGRAM OF DISPLAY AND KEYBOARD CARD OF BLOCK DIAGRAM OF DISPLAY AND KEYBOARD CARD OF COMCON/RAPCONCOMCON/RAPCON
8279 SWITCH
74138
74145
LEDMATRIX
9 * 8
CONNECTORFOR
KEYBOARD
ULN2003
DATA
IRO
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1
345
7
2
89
10111213
6
141516171819202122232425262728293031323334
+-
RL1
RL2
RL3
RL4
RL5
RL6
RL7
RL8
RL9
RL10
RL11
RL12
RL13
RL14
RL15
RL16
RA
PPIN
G M
OT
OR
ON
CO
MM
AN
D
-+
24V
DC
TB
2/13
TB
2/10
DA
TA
CO
MM
UN
ICA
TIO
N C
AR
D
RELAYCARD
RAPPER RELAY CARD - MOTOR ON COMMAND
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04/08/23 Copyright 2006 BHEL, Ranipet 29
DISPLAYCARD
CPUCARD
POWERSUPPLY CARD
RAPCON - 1
5 6 7 8 1 2 3 4 5 6 7 8 9 10 11 12 13 14 1516 17 18
} TO INPUT CARD
TO RELA CARD
LP7
24VAC
COMM.LOOP
COMM.LOOP
TB 1
DATA COMMUNICATION CARD
P N24V DC
GND
- - - + + +
TO ANN.CKT
TXR
24V AC
TO IN
PUT
CA
RD
TO R
ELA
CA
RD
4A
K29
6A
SUM ALARM TB2
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04/08/23 Copyright 2006 BHEL, Ranipet 30
RAPCON FUNCTION SELECTION RAPCON FUNCTION SELECTION
1999.05.19 10:23:45
SETFUNCTION
9. PROGRAMSET NO?
8. DISPLAY REAL TIME?
7. DISPLAY TIMES?
1. PASSWORD?
2. SET RAPPER TIMES?
3. SET REAL TIME?
4. SET AUTO ON/OFF?
5. SET MANUAL ON/OFF?
6. SET PROGRAM SETNO?
10. RAPCON ADDRESS?
11. RESET ALARM?
NEXT FUNCTION NO =
To reach a function with function 1 to 6 the RAPCON must be in LOCAL mode
Access to functions 2 to 6 possible only if pass word is answered correctly.
Acess to functions 7 to 11 does not require answering the pass word.
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04/08/23 Copyright 2006 BHEL, Ranipet 31
To reach next function number either press the required number meant for the function and press enter yes (OR) press set function repeatedly till the required function is displayed.
NEXT FUNCTION NO =
NEXT FUNCTION NO = 7 7 DISPLAY TIMES ?
7
ENTERYES
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04/08/23 Copyright 2006 BHEL, Ranipet 32
DATA COMMUNICATION CARDDATA COMMUNICATION CARD
FUNCTIONSFUNCTIONS:
Provides communication path between COMCON RAPCON & BAPCON Provides Rs-232-C serial communication between P.C. & COMCON. Provides hardware communication by-pass in case of power
failure/unit faulty. Extends sum - alarm signal for external annunciation. Provides 24V A.C. power supply to COMCON / RAPCON. Provides isolated 24V DC power supply to relay card & digital buffer
card. LED indication in case of 24V DC power supply fuse failure.
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04/08/23 Copyright 2006 BHEL, Ranipet 33
RAPCONRAPCON--2424
Supports up to 12 fields Hot-Standby feature Real Time Clock (RTC) User set parameters
Stored in NVRAM Labeling of outputs Isolated Inputs and
Outputs
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04/08/23 Copyright 2006 BHEL, Ranipet 34
RAPCON-IIRAPCON-II
RS-485 based network Only Remote operation Concealed inside the
panel RTC and NVRAM Lesser components
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Remote Terminal UnitRemote Terminal Unit
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RTURTU
Light weight Hand held unit
Graphical Display 64x128 pixel LCD Membrane keypad RS-485 network User interface unit for
BAPCON-II, RAPCON-II
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04/08/23 Copyright 2006 BHEL, Ranipet 37
RTUsigmaRTUsigma
Graphical User Interface 240x128 pixel LCD Tactile membrane
keypad Open standard Multi
master protocol communication
Parameter trending Alarm logging Flash based
programming
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Integrated Operating SystemIntegrated Operating System
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NEED FOR COMPUTER CONTROL OF ESPsNEED FOR COMPUTER CONTROL OF ESPs
Tedious manual tuning of parameters in each control. Status monitoring of large number of fields. Optimisation of ESP parameters. The need of supervision & control of ESP from UCB. Data logging, alarm logging & Graphical representation
of precipitator parameters. Communication with plant computer.
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IOS CONSISTS OF …..IOS CONSISTS OF …..
BAPCON
RAPCON
IOS - PC
BHELs advanced precipitator controller.
Rapper controller.
Multitasking real time PC.
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04/08/23 Copyright 2006 BHEL, Ranipet 41
FUNCTIONS OF IOS - PCFUNCTIONS OF IOS - PC
Controls & monitors BAPCONs & RAPCONs. Closed loop control of ESP through….
Opacity algorithm. Rapping set no. Algorithm. Rapping power off algorithm. Rapping time factor algorithm. Optimiser algorithm.
Centralised monitoring & control from UCB. Alarm monitoring & print out of status.
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ADVANTAGES OF IOSADVANTAGES OF IOS Wide C.R suitable for Indian conditions. Automatic optimisation of C.R. base charging. Peak & valley KV measurement. Pre-programmed rapping sequences. Reduces emission & energy consumption. Pays back investment in couple of years. Software on ROM cards. Indigenous Hardware & Software. Upgradable. Maintenance support. Customising to needs.
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IOS SOFTWARE MENUSIOS SOFTWARE MENUS BAPCON MENU. RAPCON MENU. PRINTER MENU. SETUP MENU.
Opacity basedata. BAPCON basedata. Rapcon basedata. Communication interval time. Algorithm basedata. Password setting. Opacity basedata. Opacity/dust correlation. Precipitator basedata.
ALGORITHM. Opacity algorithm. Optimiser algorithm. Rapping factor algorithm. Rapping power algorithm.
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ALGORITHMS IN IOSALGORITHMS IN IOS
• Opacity algorithm• Rapping power off algorithm• Rapping set no. Algorithm• Optimizer algorithm• Rapping power factor algorithm• Auto selection of opacity monitor based on ID
fan status.
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04/08/23 Copyright 2006 BHEL, Ranipet 45
RAPPING FACTOR ALGORITHMRAPPING FACTOR ALGORITHM
100
75
50
25
25.5
4.0
1.0
25% 750% 100%Boiler load
Boiler load max set
Boiler load min.set
Tim
e fa
ctor
Rep
etiti
on fr
eq %
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OPTIMIZER ALGORITHMOPTIMIZER ALGORITHMC.R
OPTIMISATION S/W
TAKE VI CURVE & TESTFOR VALLEY KV DROPPINGFOR OPERATING CHARGE
RATIO
DROOPING ?
INCREASE C.R. & SWITCH OFF OPTIMUM REACHED
LED.
DECREASE C.R & TEST FORDROOPING
YES NO
DROOPING ?
SWITCH OFF OPTIMUM REACHED
LED.
NO INCREASE C.R & SWITCH ON OPTIMUM
REACHEDLED.
YESRET
RET
RET
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04/08/23 Copyright 2006 BHEL, Ranipet 47
NT-IOSNT-IOS
Windows based IOS Integrated Datalogging Track Ball & Mouse
operation Industrial Computing
platform Industrial grade desktop
mounting
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NT-IOSNT-IOS
Integrated Operating System on Integrated Operating System on Windows NT platformWindows NT platform
Bharat Heavy Electricals Limited, Ranipet
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Main featuresMain features
• Graphical User Interface• Trend curves display• Compatibility with latest printers• User friendly help features• Information access through Intranet• can be upgradable easily
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GUIGUI
User friendly windows screens for giving command to different controllers and displaying the ESP field status.
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Trend curves displayTrend curves display
• VI curve for each field• Line Graphs for
• Current , Voltage, • Spark rate, • Opacity and • boiler load
• Bar chart for Analog input of Opacity and boiler load
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Compatibility for PrintersCompatibility for Printers
• All printers supported by Windows NT can be used for Text log , Graph log and VI curves
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User friendly help featuresUser friendly help features
• Help feature covers the Technical and operating details of this package with Images.
• Context sensitive help for each screen is available.
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Information access through IntranetInformation access through Intranet
• ESP field operating parameters like TR ON/OFF , current , voltage, Rapper On/OFF etc. are made available to all intranet users through a JSP software.
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Future upgradeFuture upgrade
• New customer requirements can be added easily
• Can be upgraded easily for latest / future versions of Microsoft Windows Operating Systems. ( Eg. Windows 2000 and latest)
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Software ArchitectureSoftware Architecture
Windows NT O.SControls ActiveX controlsDevice Drivers
Forms & Modules
VB application program
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Software detailsSoftware details• Developed in VB• 35 Forms for user input and output• 8 modules for start-up & algorithms• Active X controls
• MSCOM for communication• Graphics Server for Graphs
• Dedicated Help Package is used• Device driver for Reading Digital & Analog
channels
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Salient FeaturesSalient Features• Pass word protection at two levels• Communication channel health monitoring
& indication at relevant forms• Operator’s input validation • Warning messages• Web server to publish WEB page
developed in JSP• Successfully tested at Mettur TPS &
Ramagundam STPS
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NT-IOSPC
BAPCON1 BAPCON2
NT-IOS HARDWARE ARCHITECTURENT-IOS HARDWARE ARCHITECTURE
RAPCON-n RAPCON2
BAPCON-n
RAPCON-1
Boiler loadOpacity
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Hardware Configuration of NT-IOSHardware Configuration of NT-IOS
Opacity monitor & calib.input
Boiler load
DATA-LOGGER PC
PRINTER
SUPPOR TINS
HEATER
SHAFTINS
HEATER
ESP
BUS SECTI ON 1
ESP
BUS SECTI ON 2
FIELD- 1
FIELD- 2
FIELD- 3
FIELD- 4
FIELD- 5
FIELD- 6
FIELD- 7
FIELD- 8
HOPPERHEATER
ESP
1 2
ALILOW
ESP
1 2
BHELSTATCON-E1
REBOOT
ALIVE
SUPPORTINS
HEATER
SHAFTINS
HEATER
ESP
BUS SECTI ON 1
ESP
BUS SECTI ON 2
FIELD-1
FIELD-2
FIELD-3
FIELD-4
FIELD-5
FIELD-6
FIELD-7
FIELD-8
HOPPER
HEATERESP
1 2
ALI
LOWESP
1 2
BHELSTATCON-E2
REBOOT
ALIVE
RAPCON 4
RAPCON 1
BAPCON 1
BAPCON 2
BAPCON 3
BAPCON24
NT- IOS PC
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Hardware Configuration of NT-IOSHardware Configuration of NT-IOS
Opacity monitor & calib.input
Boiler load
DATA-LOGGER PC
PRINTER
SUPPORTINS
HEATER
SH AFTINS
HEAT ER
ESP
BUS SECT ION 1
ESP
BUS SECT ION 2
FIELD-1
FIELD-2
FIELD-3
FIELD-4
FIELD-5
FIELD-6
FIELD-7
FIELD-8
HOPPERHEATER
ESP
1 2
ALILOW
ESP
1 2
BHELSTATCON-E1
REBOOT
ALIV E
SU PPORTINS
HEAT ER
SHAFTINS
HEATER
ESP
B US SECTION 1
ESP
B US SECTION 2
FIELD- 1
FIELD- 2
FIELD- 3
FIELD- 4
FIELD- 5
FIELD- 6
FIELD- 7
FIELD- 8
H OPPERH EATER
ES P
1 2
ALIL OWES P
1 2
BHELSTATCON-E2
R EBOOT
A LIVE
RAPCON 4
RAPCON 1
BAPCON 1
BAPCON 2
BAPCON 3
BAPCON24
NT- IOS PC
Fat Client
Thin Client
Any Pc withLan
IOS-1
IOS-2
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Opening ScreenOpening Screen
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BAPCON DisplayBAPCON Display
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RAPCON DisplayRAPCON Display
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ANALOG Display - BAPCONANALOG Display - BAPCON
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Command ScreenCommand Screen
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BAPCON CommandBAPCON Command
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RAPCON CommandRAPCON Command
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SETUP - SelectionSETUP - Selection
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SETUP-BAPCON Base DataSETUP-BAPCON Base Data
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ALGORITHM SELECTIONALGORITHM SELECTION
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Graph Log - SelectionGraph Log - Selection
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Graph LogGraph Log
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SELECT BAPCON for VI CurveSELECT BAPCON for VI Curve
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VI Curve - BAPCON1VI Curve - BAPCON1
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HELPHELP
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STATCON-D1MASTER
STATCON-D1SLAVE
STATCON-D2MASTER
STATCON-D2SLAVE
STATCON-D3MASTER
STATCON-D3SLAVE
STATCON-D4MASTER
STATCON-D4SLAVE
STATCON-E
COMCON
BAPCON -16
BAPCON - 1
IOS PC
1 - 16 DCVCONTROLLER
17 - 32 DCVCONTROLLER
HCCCONTROLLER
DAMPER, BWE
& LCCCONTROLLER
BAPCON 2
BAPCON - 3
RAPCON MASTER
RAPCON SLAVE
DDCMIS
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Hardware Configuration of IOS with NetworkHardware Configuration of IOS with Network
Opacity monitor & calib.input
Boiler load
DATA-LOGGER PC
PRINTER
RAPCON 4
RAPCON 1
BAPCON 1
BAPCON 2
BAPCON 3
BAPCON24
NT- IOS PC SERVER
Pc - 1
Pc - 2
Pc - in LAN
IOS-1
IOS-2
RS 232
LAN
RS 232 / CURRENT LOOP CONVERTER
Net08.ico
COM 1COM 2
NERWORK RJ45
CURRENT LOOP
Optional
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Common IOSCommon IOS
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CENTRALISED CONTROL & DISPLAY FOR MULTIPLE IOS’s CENTRALISED CONTROL & DISPLAY FOR MULTIPLE IOS’s
IOS #6
IOS #7
IOS #8
IOS #9
IOS #10
IOS #11
CIOS PC
RS-232C TO RS-485 CONVERTOR
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COMMON TERMINAL FOR MULTIPLE IOS’COMMON TERMINAL FOR MULTIPLE IOS’
CENTRALISED CONTROL SYSTEM CONTROL & DISPLAY FOR INDIVIDUAL SUB-
CONTROLLERS THROUGH IOS INTERFACE : RS-232C TO RS-485 PROTOCOL : MODBUS ( ASCII ) WINDOWS BASED APPLICATION SOFTWARE
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BAPCON COMMAND SCREEN BAPCON COMMAND SCREEN
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RAPCON COMMAND SCREENRAPCON COMMAND SCREEN
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RAPCON STATUS DISPLAYRAPCON STATUS DISPLAY
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CURRENT LOOP vs MULTIDROP DATAHIGHWAYCURRENT LOOP vs MULTIDROP DATAHIGHWAY
By pass relay is required in case controller is removed / fails
Network has to be physically re configured if there is a breakage in main communication line.
Low protocol overhead, more efficient at low speeds itself.
communication frames of varying sizes allowed.
Termination resistance & by pass relay is required in case controller is removed / fails.
Network has to be physically re configured if there is a breakage in main communication line.
Protocol overhead is high, therefore higher speed is must.
Communication frame size standardized. Large message will have to be split.
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Other DevelopmentsOther Developments
Wireless access between controllers Wireless access between sensors & controllers SCADA based IOS
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Thank YouThank You