Presentation on Advancements in ESP Control System
R&D Center
5/24/2012
Copyright 2006 BHEL, Ranipet
Evolution of ESP controllers in BHEL
ESP HVR CONTROL
ANALOG CONTROLLER AICE - C BAPCON
RAPPING CONTROL
AUTORAPPER SYNCHRONOUS PROGRAMMER mP BASED RAPPER CONTROLLER
RAPCON
ESP CONTROL
MANUAL CONTROL COMPUTER CONTROLLED PRECIPITATOR OPERATION IOS
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Copyright 2006 BHEL, Ranipet
High Voltage Rectifier Controllers
Basic 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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qs
EP
+
+ + + + +
Qs E p
+ + + +
F = Qs . Eav Ep . Eav Vp . Vav
x i
BACK CORONA
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Modified Intermittent Charging
Increases the base voltage More suited for high charge ratio operation suitable for high resistivity dust
Outlet emission (mg/Nm^3) 351 127 Power consumption (kW) 300 57
Conventional charging Intermittent charging
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Energy Saving
Reduction in energy costs due to modified intermittent charging
210 MW ESP
Reduction in power : 243 kW At 2 Rs./kWH and 65% duty, yearly saving : Rs. 27.7 Lakhs
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BAPCON
BHELs Advanced Precipitator CONtroller (BAPCON) Highly reliable Displays in % Local & Remote operation CR mode Warning & TRIP Alarms
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Schematics of BAPCON
Feedback control system IP65 packing
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BAPCON
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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VARIOUS DISPLAYS IN BAPCON
E H O 1 2 3 4 5 6 7 8 9 Precipitator current Precipitator voltage Sparks per minute Im limit Is limit S control Time control Stabilization time U.V. Limit C.R. Pulse current limit Repeat time Address Peak & valley voltage P Base charge L Base charge current
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ALARMS IN BAPCON
o TRIP ALARMS: o E1 - Safety chain broken. o E2 - Eprom faulty. o E3 - Power supply failure. o E4 - Over voltage o 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
o o
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Bucholtz top float.
Ash level high. Under voltage.
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SPARK DETECTOR
CURRET SIGNAL FROMTR VOLTAGE SIGNAL FROMTR
PROGRAM (EPROM) 2732 / 2764
SERIAL COM.(8251) KEYBOARD PORT 1 I/O 8155
SIGNAL CONDNG AMP. SIGNAL CONDNG AMP. PEAK & VALLEY DETCTR.
ALARMS FIRING SGNL.O/P ADDRESS SET
ANALOG TO DIGITAL CONVTR. ADC 0816)
PROCESSOR 8085
OUTPUT RELAYS
PORT 2 I/O 8155
SPARK COUNTER INDICATING LEDs
SET POINT POT. METERS.
SYNCH. SIGNAL
WATCH DOG
DISPLAY
BAPCON - DETAILED BLOCK DIAGRAM
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BAPCONplus
Engineering Unit display Designed for 660MW application VFD display Local & Remote operation CR mode Base Charge mode Warning & TRIP Alarms
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BAPCON-II
Single board design Fewer components, Higher reliability RS-485 bus based highspeed network Remote operation Concealed in HVR panel In-built rapping
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BAPCONsigma
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
19
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Rapping System
RAPCON
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 RAPCON
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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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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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COMMAND 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 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
ISOLATOR DATA COMMN. CARD REPLY CARD P.S.CARD
INPUT BUFFER CARD
BLOCK DIAGRAM OF RAPCON HARDWARE
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BLOCK DIAGRAM OF CPU CARD OF RAPCON
6.144 MHz
TIMER 0 TIMER 1
TIMER2
8254 TIMER
8085
IR 0 IR 1
EPROM 27128
EPROM 27128
RAM 6264
MICRO 8259 PIC PROCESSOR FEEDBACK FROM 8255 PPI MOTOR CONTACTS
IR 7
TX RX
8251 USART
4321
WATCH
TX RX
8251 USART 5/24/2012
DOG
8255 PPI DIP SWITCH 26
CIRCUIT Copyright 2006 BHEL, Ranipet TO MOTOR CONTACTS
BLOCK DIAGRAM OF DISPLAY AND KEYBOARD CARD OF COMCON/RAPCON
74145
DATA
74138 8279
IRO
SWITCH
LED MATRIX 9*8
CONNECTOR FOR KEYBOARD ULN 2003
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1
2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19 20 21 22 23 24 25 26 27 28 29 30 31 32 33 34
RELAY -CARD
+
RL1 RL2 RL3 RL4 RL5
RL6
RL7 RL8 RL9 RL10 RL11 RL12 RL13 RL14 RL15 RL16
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RAPPER RELAY CARD - MOTOR ON COMMAND
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RAPCON - 1
DISPLAY CARD
CPU CARD
POWER SUPPLY CARD
24V AC DATA COMMUNICATION CARD SUM TB2 ALARM P TB 1 N 24V DC - - - + + + GND
TXR
5 6 7 8
1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18
COMM.LOOP COMM.LOOP TO ANN.CKT 4A 6A LP7
} TO INPUT CARD
TO RELA CARD
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K29 24VAC
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RAPCON FUNCTION SELECTION
1999.05.19 SET FUNCTION 10:23:45
NEXT FUNCTION NO =
1. PASSWORD? To reach a function with function 1 to 6 the RAPCON must be in LOCAL mode 2. SET RAPPER TIMES? 3. SET REAL TIME? 4. SET AUTO ON/OFF? Access to functions 2 to 6 possible only if pass word is answered correctly. 5. SET MANUAL ON/OFF? 6. SET PROGRAM SETNO? 7. DISPLAY TIMES? Acess to functions 7 to 11 does not require answering the pass word.
8. DISPLAY REAL TIME?
9. PROGRAMSET NO? 10. RAPCON ADDRESS?
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11. RESET ALARM? Copyright 2006 BHEL, Ranipet
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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
ENTER YES
7 DISPLAY TIMES ?
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DATA COMMUNICATION CARD FUNCTIONS:
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 ofCopyright 2006 BHEL, Ranipet fuse failure. 24V DC power supply 5/24/2012
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RAPCON-24
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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RAPCON-II
RS-485 based network Only Remote operation Concealed inside the panel RTC and NVRAM Lesser components
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Remote Terminal Unit
RTU
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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RTUsigma
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 System
NEED 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 ..
BAPCON
RAPCON
BHELs advanced precipitator controller.
Rapper controller.
IOS - PC
Multitasking real time PC.
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FUNCTIONS 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 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 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 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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RAPPING FACTOR ALGORITHM
1.0 100 75 50 4.0
25 25.5
25% Boiler load min.set 5/24/2012
750% Boiler load max set
100%
Boiler load
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OPTIMIZER ALGORITHM
C.R OPTIMISATION S/W
TAKE VI CURVE & TEST FOR VALLEY KV DROPPING FOR OPERATING CHARGE RATIO
YES
DROOPING ?
NO
INCREASE C.R. & SWITCH OFF OPTIMUM REACHED LED.
DECREASE C.R & TEST FOR DROOPING
RET
INCREASE C.R & SWITCH ON OPTIMUM REACHED LED.
YES
DROOPING ?
NO
SWITCH OFF OPTIMUM REACHED LED.
RET
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RET
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NT-IOS
Windows based IOS Integrated Datalogging Track Ball & Mouse operation Industrial Computing platform Industrial grade desktop mounting
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NT-IOS
Integrated Operating System on Windows NT platform
Bharat Heavy Electricals Limited, Ranipet
Main 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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GUI
User friendly windows screens for giving command to different controllers and displaying the ESP field status.
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Trend 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 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 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 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 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 Architecture
VB application program Forms & Modules Controls ActiveX controls Device Drivers Windows NT O.S
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Software 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 Features
Pass word protection at two levels Communication channel health monitoring & indication at relevant forms Operators 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-IOS HARDWARE ARCHITECTURE
BAPCON1
BAPCON2
BAPCON-n
NT-IOS PC
Boiler load Opacity
RAPCON-n
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RAPCON2
RAPCON-1
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Hardware Configuration of NT-IOS
NTIOS
PC
PRINTER
DATALOGGER PC
Boiler load Opacity monitor & calib.input
BAPCO N1
ALI SUPPORT INS HEATER SHAFT INS HEATER 1 ESP BUS SECTION 1 FIELD-2 2 FIELD-1 LOW ESP
HOPPER HEATER ESP 1 2 ALIVE
ESP BUS SECTION 2
FIELD-3 REBO OT FIELD-4
FIELD-5
FIELD-6
FIELD-7
FIELD-8
STATCON-E2
BHEL
ALI SUPPORT INS HEATER SHAFT INS HEATER 1 2 FIELD-1 1 2 LOW ESP HOPPER HEATER ESP ALIVE
BAPCO N2
ESP BUS SECTION 1
FIELD-2
ESP BUS SECTION 2
FIELD-3 REBO OT FIELD-4
FIELD-5
FIELD-6
FIELD-7
FIELD-8
STATCON-E1
BHEL
BAPCO N3
RAPCO N4
BAPCON 24
RAPCO N1
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Hardware Configuration of NT-IOS
Fat
Client
IOS-2
NTIOS
DATALOGGER PC
IOS-1
PC
PRINTER
Boiler load Opacity monitor & calib.input
Thin Client
BAPCO N1
ALI SUPPORT INS HEATER SHAFT INS HEATER 1 ESP BUS SECTI ON 1 FIELD-2 2 FIELD-1 LOW ESP
HOPPER HEATER ESP 1 2 ALIVE
ESP BUS SECTI ON 2
FIELD-3 REBO OT FIELD-4
FIELD-5
FIELD-6
FIELD-7
FIELD-8
STATCON-E2
BHEL
ALI SUPPORT INS HEATER SHAFT INS HEATER 1 ESP 2 FIELD-1 1 2 LOW ESP HOPPER HEATER ESP ALIVE
BAPCO N2
BUS SECTI ON 1 FIELD-2
ESP BUS SECTI ON 2
FIELD-3 REBO OT FIELD-4
FIELD-5
FIELD-6
FIELD-7
FIELD-8
STATCON-E1
BHEL
Any Pc withL an
BAPCO N3
RAPCO N4
BAPCO N24
RAPCO N1
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Opening Screen
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BAPCON Display
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RAPCON Display
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ANALOG Display - BAPCON
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Command Screen
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BAPCON Command
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RAPCON Command
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SETUP - Selection
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SETUP-BAPCON Base Data
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ALGORITHM SELECTION
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Graph Log - Selection
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Graph Log
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SELECT BAPCON for VI Curve
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VI Curve - BAPCON1
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HELP
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DDCMIS
RAPCON MASTER
RAPCON SLAVE
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Hardware Configuration of IOS with Network
Pc - 1
IOS-2 IOS-1
NERWORK RJ45
RS 232 / CURRENT LOOP CONVERTER
Optional NT- IOS PC SERVER
COM 1 COM 2 PRINTER
DATALOGGER PC
RS 232
L A N
Pc - 2
CURRENT LOOP BAPCON 1
Boiler load Opacity monitor & calib.input
BAPCON 2
Pc - in
LAN
BAPCON 3
RAPCON 4
BAPCON2 4
RAPCON 1
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Common IOS
CENTRALISED CONTROL & DISPLAY FOR MULTIPLE IOSs
CIOS PC
RS-232C TO RS-485 CONVERTOR
IOS #6
IOS #7
IOS #8
IOS #9
IOS #10
IOS #11
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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
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RAPCON COMMAND SCREEN
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RAPCON STATUS DISPLAY
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CURRENT 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 Developments
Wireless access between controllers Wireless access between sensors & controllers SCADA based IOS
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Thank You
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