ENGG/GEN/001

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It must not be used directly or indirectly in anyway detrimental to the interest of the company.
The information on this document is the property of Bharat Heavy Electricals Limited.

TITLE : OPERATING INSTRUCTIONS

COPY RIGHT AND CONFIDENTIAL

PRODUCT : maxDNA BASED DCS

APPROVED BY :
Revision 01 07/05/2005
Sd/-
Revision 02 20/07/2005 G.Ganapathiraman
PREPARED ISSUED DATE
sd/-
G.S Rotti ENGG 10/03/2005
 ENGG/GEN /001
OPERATING INSTRUCTIONS
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REVISION HISTORY SHEET

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The information on this document is the property of Bharat Heavy Electricals Limited.

REV DATE NATURE OF CHANGE REASON PREPARED APPROVED

No. BY BY
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00 10/03/2005 FIRST ISSUE -- GSR GGR

01 07/04/2005 Clauses marked (R1) MA feedback GSR GGR

changed

02 20/07/2005 Clauses marked (R2) changed Operation with GSR GGR

Version 3.4

APPROVED BY :
Revision 01 07/05/2005
Sd/-
Revision 02 20/07/2005
G Ganapathiraman

PREPARED ISSUED DATE

Sd/-
G.S Rotti ENGG 20/07/2005
 OPERATING INSTRUCTIONS ENGG/GEN/001

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A. GENERAL

1. Handle the Electronic Modules only after wearing the anti static wrist
band provided in each panel for this purpose.
It must not be used directly or indirectly in anyway detrimental to the interest of the company.

2. Carry the modules only in anti static bag.

B. DPU
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1. Do not attempt full DPU down load to an active in a running plant (R1)

2. It is recommended that logic change in the DPU configuration should

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be carried out in Tools and incremental down loaded into the DPU.
However tuning constants can be changed on line. For incremental
down load disable backup, down load into secondary, takeover and
enable backup.

3. On line changes using graphic configurator in the Closed Loop logics

should be made only after putting the loop to manual.

4. Do not make changes to time setting (Critical/High/Normal) in DPMS,

using point Browser.

5. Do not edit text fields (like short description, Desc,) on line including
any HID and references.

6. Do not change programs of MFT and Turbine protection DPUs even in

off line without permission of engineering agencies.

7. Make it a practice to view DPU4e status picture and Network Status

picture regularly. It will help identify any problems in DPU and Network.

8. The alarms provided for the DPU status should be brought to the notice
of the concerned immediately. Health Log should be running on any
station running event collector. (R1)

9. Any DPU which goes into Fatal condition should be soft reset.

10. All DPUs except those in MFT panels are redundant pairs. Ensure that
Backup is enabled for all redundant DPUs.

11. Maintain record if a DPU has to be operated in Stand alone mode or

backup enabled without the partner.

12. Ensure that the mode switch of all the DPUs is set to F.

13. Ensure that the mode of the DPUs switch is not in position B. This will
erase the program in case of power failure and restoration.
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14. Ensure that the key switch is in proper position as per the following
table.
Run Normal execution of control logic; DPU
accepts database changes.
Lock Normal execution of control logic ( DPU
It must not be used directly or indirectly in anyway detrimental to the interest of the company.

will not accept database changes in this

mode).
The information on this document is the property of Bharat Heavy Electricals Limited.

Off-line Will scan inputs but not generate any

outputs. (In the future it also will accept
database changes in this mode).
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Between the After short time delay will place the DPU
Valid Positions in the Offline mode. If the reset button is
pressed in this mode a hard reset will
be generated to the DPU. This will cause
the DPU to reset without saving the
current database.

15. Always keep the DPU4e in LOCK mode.

16. Remove the keys from MFT and Turbine Protection DPU after keeping it
in lock mode.
17. Following procedure should be adopted for starting the DPUs after
power loss and resumption (for paired and stand alone DPUs)
a. Turn the Key switches of both the DPUs to OFF LINE position.
(Fully counter clockwise)
b. Switch on the power to the panel.
c. After DPU boots up, check and ensure that the configuration
(program) is ok. (by checking the SvcCount)
d. As per process requirements check then change/set the outputs.
e. Then turn the active DPU key switch to RUN position.
f. Take the loops to AUTO if required as per process requirement.
g. Then turn the key switch of inactive DPU to RUN position.
h. Check as per process requirement and then put key switch of both
the DPUs in LOCKED mode.

18. Always check for freeze outputs after DPU download. Change /set the
outputs as per process requirement. Then un-freeze the outputs.

19. Have a routine check of the DPU battery health status. The health
indication is available on the front plate of DPU and on the OWS DPU
status picture.

20. Do not use a DPU with unhealthy battery. This can lead to program loss
in case of power failure.

21. Do not keep DPU in On line mode after restoring from power loss.
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22. When operating with V3.4, whenever a DPU goes to fatal, the cause for
going to fatal is written in the attribute DPU AlmReason in
\system\backup. This has to be noted and corrective action taken before
resetting the DPU. (R2)

23. When operating with V3.4, when hashes appear on picture, close the
It must not be used directly or indirectly in anyway detrimental to the interest of the company.

picture. Do not open the picture till a good picture is closed in that
workstation. (R2)
The information on this document is the property of Bharat Heavy Electricals Limited.

24. When operating with 3.4, commands can be given from a picture that has
hashes. However the status of feedback is not updated. (R2)
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C. HMI

1. Check with anti virus software any CD/USB drive before using in the
system.

2. Unless absolutely essential do not install anti virus software in the OWS.

3. Operators may be advised not to invoke Explorer program in any of the

OWS.

4. None of the MS office programs should be installed in the maxSTATIONS.

5. All CD ROM drives of maxSTATIONS should be disabled.

6. Close all the Pop ups as soon as the intended operation is completed.

7. Call only Six Pop ups per picture at a time.

8. Do not call more than 3 instances of the same picture.

9. Do not repeatedly call the same picture.

10. Wait till a picture is completely displayed before closing it or before

calling a new picture.

11. Change password for security 9 on all workstations regularly. It is

important that security 9 be the same.
(R1)

12. Keep the operating security at low level to avoid accidental reset, reload
and manual changeover by operator.

13. Do not run more than one instance of maxVUE/point browser in OWS.

14. Ensure that Event collector program is run only in two maxSTATIONS.
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15. Ensure that Alarm list server is run only in two maxSTATIONS.

16. Dongle of Engineering station should not be used in any other OWS.

17. Make it a practice to acknowledge regularly all the system and process
It must not be used directly or indirectly in anyway detrimental to the interest of the company.

alarms and take appropriate action on system alarms.

The information on this document is the property of Bharat Heavy Electricals Limited.

18. Take backup of the last compacted Event file created every day. (R1)

19. Take a one time backup of the following:

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a. customs\config and customs\display from engineering stations

b. customs\sbp, customs\database from all OWS
c. customs\history from historian, customs\links for maxLINKS and
customs\opc from OPC station
d. customs\reports from report server (from historian where report
server is running).
e. Mxsstorageroom\configurations from each maxSTORIAN station
(R1)

20. Ensure that all the printers (especially SOE and system Events printers)
are on line.

21. Set up event logger in only two stations, if required. Events should be
viewed using Event summary display in maxVUE under system menu.
(R1)

22. Use default login 0 at stations remote to the control room to restrict any
casual user. Use operator login 3 in control room. (R1)

23. The passwords for different security levels 1 to 9 must be the same on
every station in the control network. (R1)

24. The administrator and engineer password need not be the same in all the
stations. (R1)

D. HARDWARE

1. Failed module must be replaced immediately. In particular, failed

redundant I/O module should be immediately be replaced. A failed
redundant module will not allow the DPU to become active.

2. While replacing module ensure that the jumper setting is set as per
requirement and fuse is of correct rating.

3. For replacing a failed DPU refer DPU4e Hardware guide.