TM

MicroNet™ Plus & TMR 26th Feb. 2011

User Group Seminar - Saudi Aramco - RTR

CONTROLLING the power of ENERGY

This presentation is intended only for the individual or entity to which it is addressed and may contain information that is the Confidential and/or Proprietary Information of

Woodward Governor Company, the disclosure of which may be in violation of applicable law. If you are not the intended recipient, or an employee or agent responsible for

delivery to the intended recipient, you are hereby notified that any dissemination, distribution, or copying of this message is strictly prohibited and you are requested to notify

us immediately by telephone.

Topics of Presentation

(2)

PROPRIETARY INFORMATION

MicroNet™ Application Overview.

MicroNet™ Chassis and Module Architecture.

TMR Voting structure.

DCS Networking & MicroNet™ Plus.

GAP™ & Software Determinism.

Compressor Compressor

PT

PT

FT

PT

FT

Discharge Pressure No. 2

Side stream Pressure

Side stream Flow

Suction Pressure No. 1

Suction Flow No. 1

Recycle Valve No. 2

Recycle Valve No. 1

motor current Signal

Torque converter or Gear Throttle Valve

Speed input Signal

Programmable Discrete Inputs

Programmable Analog Inputs

Programmable Discrete Outputs

Programmable Analog Outputs

AI

AO

DO

Ethernet, RS232, RS422, RS485 Ports

MicroNet™ Plus

For

Motor Driven Compressor

DCS and Eng Work Station

(3)

PROPRIETARY INFORMATION

Compressor Compressor

PT

PT

FT

PT

FT

Discharge Pressure No. 2

Side stream Pressure

Side stream Flow

Suction Pressure No. 1

Suction Flow No. 1

Recycle Valve No. 2

Recycle Valve No. 1

Programmable Discrete Inputs

Programmable Analog Inputs

Programmable Discrete Outputs

Programmable Analog Outputs

AI

AO

DO

Ethernet, RS232, RS422, RS485 Ports

DCS and Eng Work Station

Compressor Discharge Pressure

Turbine Inlet Temperature

Gas Generator Speed

Fuel Valve Demand Signal

Power Turbine Speed

Exhaust Gas Temperature

(4)

PROPRIETARY INFORMATION

MicroNet™ Plus For

Integrated Turbine &

Compressor Control

PT

T&T Valve PT

Exhaust Pressure Signal

PT

PT

HP

LP IP

HP Actuator Demand Signal

IP Actuator Demand Signal

LP Actuator Demand Signal

Turbine Speed

LP Extraction Pressure Signal

HP Extraction Pressure Signal

Inlet Pressure Signal

Generator

PTs &

CTs

DCS / OCP

505DE

Watt

Xducer

Synchronizer

E.W.S

MicroNet™ Plus for STG controls

MicroNet™ TMR MicroNet™ Plus

MicroNet™ Hardware

(6)

PROPRIETARY INFORMATION

MicroNet™ Plus Hardware

(7)

PROPRIETARY INFORMATION

Power Supply Module

CPU

I/O Modules (6 or 12)

CPU – 2nd

Power Supply – 2nd

MicroNet™ Plus I/O Modules

(8)

PROPRIETARY INFORMATION

Cable

I/O Module

Field Termination

Module (FTM)

Field wiring or

Marshalling

Chassis

MicroNet™ Hardware

(9)

PROPRIETARY INFORMATION

I/O A

I/O B

FTM

FTM

Field Device

Field Device

Card level redundancy lost does not mean Field level redundancy lost

MicroNet™ Hardware

(10)

PROPRIETARY INFORMATION

I/O A

I/O B

I/O C

TMR FTM

TMR FTM

Field Device

Field Device

Card level redundancy lost does not mean Field level redundancy lost

MicroNet™ Supports Simplex, Dual,

Triplicate Inputs

APPLICATION

3 INPUT

REDUNDANCY

MANAGER

A_3_RM

TMR

FTM

INPUT

PTB

TMR

FTM

INPUT

PTC

SELECTED

APPLICATION

VALUE

3 INPUT

REDUNDANCY

MANAGER

A_3_RM APPLICATION

3 INPUT

REDUNDANCY

MANAGER

A_3_RM

CHANNEL FAULT

& RANGE CHECK

CHANNEL FAULT

& RANGE CHECK

CHANNEL FAULT

& RANGE CHECK

I/O & VOTE A

I/O & VOTE B

I/O & VOTE C

CHANNEL FAULT

& RANGE CHECK

CHANNEL FAULT

& RANGE CHECK

CHANNEL FAULT

& RANGE CHECK

I/O & VOTE A

I/O & VOTE B

I/O & VOTE C

Typically the median is used if 3 sensors are present & the HSS is used it 2 signals are present. These are DEBUG tunables in the GAP .

TMR

FTM

INPUT

PTA

CHANNEL FAULT

& RANGE CHECK

CHANNEL FAULT

& RANGE CHECK

CHANNEL FAULT

& RANGE CHECK

I/O & VOTE A

I/O & VOTE B

I/O & VOTE C

APPLICATION

3 INPUT

REDUNDANCY

MANAGER

A_3_RM

(11)

PROPRIETARY INFORMATION

TMR Output Drivers

TMR Analog Output Hardware Sharing and Fault Monitoring

(12)

PROPRIETARY INFORMATION

Motorola 5200 CPU Card Reset Sw & LED

2 Ethernet Ports

2 Real Time Net Pt

Woodward Debug Pt

Status LEDs

Serial Comm. Port

CAN Ports

COMPUTING POWER 700 mips @ 400MHz MEMORY 64 MB Flash - 128 MB RAM Supports multiple GAP Applications Supports multiple data logs Program Loading On Board Ethernet port - 10/100 BPS AppManager via Ethernet port VX-Works Operating System Communication Network Modbus Serial link – ASCII or Binary, Servlink Modbus Ethernet – UDP or TCP/IP Built in OPC – 10/100 Base T, Real Time

MicroNet™ Plus – CPU 5200

(13)

PROPRIETARY INFORMATION

Setting up Ethernet Network

(14)

PROPRIETARY INFORMATION

• Ethernet Ports on each CPU have a unique IP address.

• Ethernet Ports 1 and 2 must be on different Subnets.

• DCS & EWS connect to the CPU’s Ethernet port either directly or through a network switch.

NOTE This module has been factory configured with fixed Ethernet IP addresses of

Ethernet #1 (ENET1) = 172.16.100.1, Subnet Mask = 255.255.0.0

Ethernet #2 (ENET2) = 192.168.128.20, Subnet Mask = 255.255.255.0

TCP/IP

EWS & Printer

PCN – 1

PCN – 2

PIB R2 Cabinet # K-402 Cabinet # K-602

Ethernet / FO SW.

Eth. / FO Sw.

Cabinet # K-502

CCR

DCS/ ALMS

EWS & Printer

Cabinet # K-401

DCS DCS DCS DCS

TCP/IP TCP/IP TCP/IP TCP/IP

PIB R1 Cabinet # K-301

Ethernet / FO SW.

EWS & Printer

DCS

TCP/IP

Plant Automation Network #2

( LAN SWITCH #2 )

RS485 ( Loop # 1 )

RS485 ( Loop #2 )

( LAN SWITCH #1 )

EWS

LAN SW#1

LAN SW#2

RS485 Loop

RS485 Loop

EWS ( LAN SWITCH #2 )

RS485 ( Loop # 1 )

( LAN SWITCH #1 )

RS485 ( Loop # 2 )

EWS

ALMS System

( LAN SWITCH #1 )

( LAN SWITCH #2 )

DCS Modbus RS485 Redundant

DCS

DCS Modbus RS485 Redundant

PIB - 4

PIB - 2

PIB - 3

EWS

CCR

Plant Automation Network # 1

( LAN SWITCH #1 )

DCS

PIB - 1 A

EWS

( LAN SWITCH #1 )

( LAN SWITCH #2 ) ( LAN SWITCH #2 )

RS485 ( Loop # 1 ) RS485 ( Loop # 1 )

RS485 ( Loop # 2 ) RS485 ( Loop # 2 )

DCS RS485

EWS

PIB - 1 B

MicroNet™ Plus & DCS/ HMI/ EWS

(16)

PROPRIETARY INFORMATION

GAP™ (Graphical Application Programmer )

17

A Windows™ based, high level, block-oriented programming language (IEC 1131)

Deterministic behavior (rate groups)

Self-documenting (Pictures-to-Code)

Created specifically for high speed application of turbine & compressor control.

The GAP™ program has sophisticated algorithms and timing control that have been rigorously proven at Woodward (since 1984)

The GAP ™ program allows engineers and field service personnel to concentrate on control engineering instead of software development

Facilitates Code Reuse – Graphical applications are easily portable to new hardware platforms

Real Time Operating System (RTOS)

Graphical Application Program

(18)

PROPRIETARY INFORMATION

18

Proprietary Information

• Monitor GAP uses SOS to communicate to the control for live updates to block outputs.

Software Determinism

(19)

PROPRIETARY INFORMATION

• Typical Definition of Determinism Doing the same thing at the same time, every time, for a given

application.

• Loading Affects Determinism Adding tasks to the program may change its deterministic nature as it

adds execution time.

Since each task is performed at a different time interval, the total execution time of all the tasks changes.

This changes the recursion rate to a new value, which is different but still deterministic.

Are the system’s dynamics effected?

Task 1,2,3,...lastTask 1,2,3,...last Task 1,2,3,...last Task 1,2,3,...last

X time X timeX timeX time

Task 1,2,3,.last+1

X+1 time

Task 1,2,3,.last+1 Task 1,2,3,.last+1 Task 1,2,3,.last+1

X+1 time X+1 time X+1 time

Software Determinism

(20)

PROPRIETARY INFORMATION

• Other control suppliers may not see this as a problem since they still know when tasks are being run. But, making changes to the recursion rate may change the performance of critical control.

• Woodward does not accept rate group slip! If a task is set to run every 5 ms, it runs every 5 ms – not faster – not slower.

All RGs

schedule

on major

Only RG

#5

schedule

RG #5 and

RG #10

schedule

Only RG

#5

schedule

RG #5, #10

and

#20Schedul

Only RG

#5

schedule

RG #5 and

RG #10

schedule

Only RG

#5

schedule

RG #5, #10

#20, #40

schedule

Only RG

#5

schedule

RG 5

RG 10

RG 20

RG 40

RG 80

Free

Time

5mS

Tick #2

5mS

Tick #3

5mS

Tick #4

5mS

Tick #5

5mS

Tick #6

5mS

Tick #7

5mS

Tick #8

5mS

Tick #9

5mS

Tick #1

5mS

Tick #10

All RGs

schedule

on major

Only RG

#5

schedule

RG #5 and

RG #10

schedule

Only RG

#5

schedule

RG #5, #10

and

#20Schedul

Only RG

#5

schedule

RG #5 and

RG #10

schedule

Only RG

#5

schedule

RG #5, #10

#20, #40

schedule

Only RG

#5

schedule

RG 5

RG 10

RG 20

RG 40

RG 80

Free

Time

5mS

Tick #2

5mS

Tick #3

5mS

Tick #4

5mS

Tick #5

5mS

Tick #6

5mS

Tick #7

5mS

Tick #8

5mS

Tick #9

5mS

Tick #1

5mS

Tick #10

All RGs

schedule

on major

Only RG

#5

schedule

RG #5 and

RG #10

schedule

Only RG

#5

schedule

RG #5, #10

and

#20Schedul

Only RG

#5

schedule

RG #5 and

RG #10

schedule

Only RG

#5

schedule

RG #5, #10

#20, #40

schedule

Only RG

#5

schedule

All RGsscheduleon major

tick

Only RG#5

schedule

RG #5 and

RG #10schedule

Only RG#5

schedule

RG #5, #10

and #20

schedule

Only RG#5

schedule

RG #5 and

RG #10schedule

Only RG #5

schedule

RG #5, #10

#20, #40

schedule

Only RG#5

schedule

RG 5

RG 10

RG 20

RG 40

RG 80

Free

Time

5mS

Tick #2

5mS

Tick #3

5mS

Tick #4

5mS

Tick #5

5mS

Tick #6

5mS

Tick #7

5mS

Tick #8

5mS

Tick #9

5mS

Tick #1

5mS

Tick #10

RG 5

RG 10

RG 20

RG 40

RG 80

Free

Time

RG 5

RG 10

RG 20

RG 40

RG 80

Free

Time

5mS

Tick #2

5mS

Tick #3

5mS

Tick #4

5mS

Tick #5

5mS

Tick #6

5mS

Tick #7

5mS

Tick #8

5mS

Tick #9

5mS

Tick #1

5mS

Tick #10

5mS

Tick #2

5mS

Tick #2

5mS

Tick #3

5mS

Tick #3

5mS

Tick #4

5mS

Tick #4

5mS

Tick #5

5mS

Tick #5

5mS

Tick #6

5mS

Tick #6

5mS

Tick #7

5mS

Tick #7

5mS

Tick #8

5mS

Tick #8

5mS

Tick #9

5mS

Tick #9

5mS

Tick #1

5mS

Tick #1

5mS

Tick #10

5mS

Tick #10

Software Determinism

(21)

PROPRIETARY INFORMATION

• Execution Order Enhances Determinism

Being able to define the specific execution order in

which tasks are performed assures that the proper

information is used by subsequent tasks.

Task 2Task 1 Task 9Task 8

Task 5Task 4Task 3

Task 7Task 6Task 10

Scan Time effect 10mSec. Vs 160mSec :

Software – 10mSec Rate Group

(22)

PROPRIETARY INFORMATION

Anti-Surge Valve Demand

Calculated Operating Point

S_PV

Raw Flow Input – Flow Element dP

The control response returns the compressor

operating point to a safe condition.

The primary closed-loop controls cannot

prevent the operating point from reaching

the Surge Limit Line—A surge occurs.

The compressor is unloaded.

Closed-loop controls begin to open the

Anti-Surge Valve as the operating point

moves below setpoint.

Scan Time effect 10mSec. Vs 160mSec :

Software – 160mSec Rate Group

(23)

PROPRIETARY INFORMATION

Raw Flow Input – Flow Element dP

Scan Time effect 10mSec. Vs 160mSec :

Result

(24)

PROPRIETARY INFORMATION

Number of undetected surges 0 9

Number of surges after initial detection 0 1

Time to initial detection 50ms 1400ms

Time from detection to recovery 74ms 322ms

• Recursion rate conclusions:

10ms Control 160ms Control

MicroNet™ Safety Certification

(25)

PROPRIETARY INFORMATION

TM

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