ELECTRONICS DIVISION, BANGALORE

maxDNA
Dynamic Network of Applications
the Industry Standard Process Control and
Enterprise Management System

Plant--wide Unified Automation Solution.

Plant

CE/MKTG/EDN : July:2007
CE/MKTG/MGK/EDN Jan 2006
TOTAL CONTROL SOLUTIONS
 ELECTRONICS DIVISION, BANGALORE

Power
Installed base in...
Chemicals - India
Fossil fired power
plants - coal, oil and
gas, combined cycle
Cogeneration plants
Hydro Power Plants
Cement, Glass &
Ceramics
Petroleum - Brazil
Primary Metals
Chemicals
Petroleum
Water & Wastewater
Treatment
Incineration
Hydro Power

CE/MKTG/EDN : July 2007

TOTAL CONTROL SOLUTIONS
 ELECTRONICS DIVISION, BANGALORE

System introduction Control level

Distributed
Processing Unit
(DPU)
System 24V

I/O Bus
8 pack rack Connector
I/O Bus
Connectors
Field 48V

(DPU4F and I/O) Field 24V

I/O Modules Eight-pack rack

D I I I
Remote Processing P O O O
I/O signals

Unit (RPU).. D
P
I
O
I
O
I
O
U
System Cabinets
I I I I
O O O O

CE/MKTG/EDN : July 2007

TOTAL CONTROL SOLUTIONS
 ELECTRONICS DIVISION, BANGALORE

HMI ... maxSTATIONS Generic

name for .

Operator Stations
maxVUE Workbench

Engineering Station

maxSTORIAN

Remote maxVUE

maxLINKS

maxDNA
maxNET GT Controls
TSI
100 Mbps (full PLCs
Numerical Relays
duplex) External systems
IEEE802.3u
CE/MKTG/EDN : July 2007
TOTAL CONTROL SOLUTIONS
 ELECTRONICS DIVISION, BANGALORE

REMOTE maxVUE

Plant information network

maxSTATIONS
ENGINEERS
STATION / maxSTORIAN

Redundant 100 Mbps maxNET

maxLINK

FIBRE OPTIC
LINK
REMOTE PROCESSING UNITS (RPUs)
PLANT SUB-SYSTEMS

TYPICAL CONFIGURATION DIAGRAM

REMOTE I/O
Serverless Configuration Scalableas large as required

CE/MKTG/EDN : July 2007

TOTAL CONTROL SOLUTIONS
 ELECTRONICS DIVISION, BANGALORE

Modular Architecture
Plug and Play System Additions
Can Grow as Your Needs Change

maxVUE maxTOOLS History Reports Firewall Applicat.

Software Backplane

Provider PLC DPU 4F

Turbine Governing, BMS ..to Plant-

Plant-wide Automation

CE/MKTG/EDN : July 2007

TOTAL CONTROL SOLUTIONS
 ELECTRONICS DIVISION, BANGALORE

UNIFIED SOLUTION FROM BHEL

CCPP / CO-GEN PLANTS
THERMAL PLANTS HRSG Controls
Boiler Controls Steam Turbine Controls
Turbine Controls Station C&I
Station C&I
HMI
HMI
Interface to GT
Power Plant SCADA
Power Plant SCADA

HYDRO PLANTS
Computerised Control &
Monitoring System Governor
Controls
Remote Operation
HMI
Optimisation Packages

CE/MKTG/EDN : July 2007

TOTAL CONTROL SOLUTIONS
 ELECTRONICS DIVISION, BANGALORE

Large Video Screen (Optional)

Remote maxVUE
(Optional)

NETWORK PRINTERS
:
DMP x 3
Operator Operator Operator Peformance ENGG.
Station # 1 Station # 2 Station # n Calcs. Station maxSTORIAN STATION
STATION A4 - COLOR
INKJET x 1

CD R/W A3 - COLOR
INKJET x 1
UNIT CONTROL DESK
(minimum/trip related)
ETHERNET SWITCH
PB STN (TRIP). maxLINKS

maxNET

ETHERNET SWITCH RPUs (I/O + DPU + Network Components)

RPU RPU RPU RPU RPU RPU RPU

RPU RPU
RPU

DPU DPU DPU DPU DPU DPU DPU DPU

I/O Modules
I/O Modules I/O Modules I/O Modules I/O Modules I/O Modules I/O Modules I/O Modules

FG # Turbine FG # Boiler FG # STN. C&I +ELECT. SWITCH YARD SCADA

LOCAL JB LOCAL JB CJC BOX LOCAL JB LOCAL JB

~
+
- E POWER MOTORS
P AMP.
T/Cs RTDs PUMPS/
ANALOG MOTORISED BREAKERS
CONTACT (4-20mA) VALVES/
INPUTS DAMPERS

Turbine Governing, BMS ..to Plant-

Plant-wide Automation
CE/MKTG/EDN : July 2007
TOTAL CONTROL SOLUTIONS
 ELECTRONICS DIVISION, BANGALORE

Distributed Processing Unit

32 Bit Processor
Redundant / Stand-alone modes
Windows CE.net Operating System
Open architecture
Dual ethernet ports, to maxNET
Dual 100 Mbps highway connections for high
speed NO intermediate servers /
communication modules
Network hardened to withstand problems
Optional IRIG input for satellite time
synchronization
High temperature tolerance and low power -
No fans, no batteries for low maintenance,
high reliability

CE/MKTG/EDN : July 2007

TOTAL CONTROL SOLUTIONS
 ELECTRONICS DIVISION, BANGALORE

Distributed Processing Unit

128 MByte RAM
64 MByte Removable Compact Flash
Non-volatile FLASH memory maintains the control
strategy configuration even if power is lost
Modulating Control, Logic, Data Acquisition
8,500 function blocks for high capacity complex
control
Event Reporting to 1 msec Resolution
User configurable program execution time
between 10 msec - 500 msec (best use of the
processor)
10,000 event queue
Directly accessible from all maxSTATIONS
Object-Oriented Configuration (totally name based)
Supports off-line simulation and testing

CE/MKTG/EDN : July 2007

TOTAL CONTROL SOLUTIONS
 ELECTRONICS DIVISION, BANGALORE

DPU Processing Capability

Multiple time classes - TX FT FT
10 msec to 500 msec
Sequence-of-Events to
1 msec resolution for X X
500 discrete inputs
Quality coding - Good,
bad, doubtful, and
substitute D1
D2
OR AND FT X
Quality code is PID
D3
propagated throughout OR
the system so that trend D4
and archive data can
also include quality
codes.
Modulating control,
logic processing, and
data acquisition

CE/MKTG/EDN : July 2007

TOTAL CONTROL SOLUTIONS
 ELECTRONICS DIVISION, BANGALORE

DPU Redundancy
maxNET

Parallel
I/O Bus

Primary and secondary are selected through

configuration
Fatal diagnostic error causes transfer in <3 msec
Secondary DPU configuration can be modified and
transfer initiated for testing purposes
CE/MKTG/EDN : July 2007
TOTAL CONTROL SOLUTIONS
 ELECTRONICS DIVISION, BANGALORE

maxPAC I/O
comprehensive line of
I/O modules

Surface mount electronics - compact, reliable, efficient

Surge withstand as per IEEE 472-1974
RFI and EMI per IEC 61000-4-2, 3 & 12
ADC resolution 15 bits + sign
Self calibrated analog modules
500V peak AC or DC Common mode voltage protection
Status indication LED for each channel
Redundant configuration possible for both analog and digital I/O

CE/MKTG/EDN : July 2007

TOTAL CONTROL SOLUTIONS
 ELECTRONICS DIVISION, BANGALORE

maxPAC I/O. saves time

and money

Module and field instrument power is bused to each module through the
I/O rack back-panel
No need for fuses - individual channels have self resetting electronic
fuses or current limiting input circuits
No special tools required for service
Hot swap of I/O modules permitted
No damage if modules are inserted in incorrect slot
Very low power requirements
Maximum addresses per maxDPU4F is 255
Each analog card is 2 addresses and each digital card is 1 address.
CE/MKTG/EDN : July 2007
TOTAL CONTROL SOLUTIONS
 ELECTRONICS DIVISION, BANGALORE

maxPAC ..
same modules used for
remote and local I/O

Bus Extender Module (BEM) for remote I/O

Maximum 2000 mts and FO cables are standard
Redundant communication
SOE points can be remote
Same modules used for remote and local I/O
Remote I/O performs just like local I/O
Identical I/O means lower investment in spare parts
CE/MKTG/EDN : July 2007
TOTAL CONTROL SOLUTIONS
 ELECTRONICS DIVISION, BANGALORE

I/O Redundancy
I/O Can be Redundant ...

I/O I/O

I/O I/O

I/O I/O ... And Shared

Redundant
DPU Bus

CE/MKTG/EDN : July 2007

TOTAL CONTROL SOLUTIONS
 ELECTRONICS DIVISION, BANGALORE

maxSTATION
True open system architecture
Seamless communications with plant and
business networks
Scaleable from small process applications
to complete plant control
On-line graphic monitoring
On-line Self-documenting configuration
Ultra high speed graphic building and
display updates
Clear Graphic displays, with animations
powered by maxSCRIPT
Popup windows for all tagged standard objects
Track select point facility
Centralised Engineering capability

CE/MKTG/EDN : July 2007

TOTAL CONTROL SOLUTIONS
 ELECTRONICS DIVISION, BANGALORE

Windows XP

Standard Operating System for all maxSTATIONS

Largest base of software applications
Strongest standards for compatibility
High reliability and security
Easily upgraded
Latest intuitive windows interface for easy
operator training and use
New suite of functions

CE/MKTG/EDN : July 2007

TOTAL CONTROL SOLUTIONS
 ELECTRONICS DIVISION, BANGALORE

maxVUE Editor Object Oriented

Comprehensive graphical Fast to learn due to industry
symbol library standard look-and-feel

Supports re-use of
graphical objects

Uses Active-x
components, bmp

For the advanced user Powerful

Visual Basic OCX objects maxSCRIPTS
Visual C++ OCX objects
Third party OCX

Endless wealth of options

... Robust..Elaborate programming is avoided
CE/MKTG/EDN : July 2007
TOTAL CONTROL SOLUTIONS
 ELECTRONICS DIVISION, BANGALORE

Typical Graphical Display

CE/MKTG/EDN : July 2007
TOTAL CONTROL SOLUTIONS
 ELECTRONICS DIVISION, BANGALORE

Typical DPU download

IP address of DPU

Primary DPU Active

Secondary DPU Inactive
& Running
& Running

configuration
down loading to DPU: Processing Bar

CE/MKTG/EDN : July 2007

TOTAL CONTROL SOLUTIONS
 ELECTRONICS DIVISION, BANGALORE

DPU Over Run Criteria

CE/MKTG/EDN : July 2007

TOTAL CONTROL SOLUTIONS
 ELECTRONICS DIVISION, BANGALORE

Graphical Configurator
for Application Building and Testing
Integrated analog and digital controls
Both graphical and database tools

Clear application
testing and
debugging

CE/MKTG/EDN : July 2007

TOTAL CONTROL SOLUTIONS
 ELECTRONICS DIVISION, BANGALORE
Two Tools with Complementary Functions
maxTOOLS
Database-
Database-oriented
Define DPUs & I/O modules
Create & edit configurations off-line
Download & upload configurations to
Real or Virtual DPUs
Full or Incremental
Import & export configuration data
from a database Access, etc.
Configuration Management
Database reports & queries
Compare configuration files
off-line or on-line vs. off-line
Update database versions
Save configuration files off-line
CE/MKTG/EDN : July 2007
maxVUE
Graphical Configurator
Connects to a DPU Real or Virtual
Fully self-describing DPU no off-
line storage of database or diagrams
is required for 100% documentation
Create & edit logic diagrams
Copy & paste function blocks
Display & print logic diagrams
Testing - Tuning
Browse configurations on-line
Edit function block connections,
parameters, descriptions, etc. on-line
Add/delete function blocks on-line
Edits are protected by security
TOTAL CONTROL SOLUTIONS
 ELECTRONICS DIVISION, BANGALORE

maxSTORIAN
Historical Data Collection and Archiving
Software for maxSTATION
Delta-Save data storage maximizes
system data capacity
Events (alarms & events), trends, reports
Time and event based report triggering
Relational database to simplify reports and
queries for data analysis
Archival storage to CD-ROM
Supports interface to plant-management
networks
Windows-XP based

CE/MKTG/EDN : July 2007

TOTAL CONTROL SOLUTIONS
 ELECTRONICS DIVISION, BANGALORE

maxLINK
maxNET Interface to external systems: GTC, TSI, PLC
networks (Coal Handling Plant, Ash Handling
Plant etc.), Numerical relays, external
systems
LDC Interface
Supports multiple simultaneous
communication protocols
Supports data transfer from other systems
and networks
Provision in DPUs also
All data available to maxSTATIONS
Plant Sub-Systems Windows-XP based
Software Backplane compatible

CE/MKTG/EDN : July 2007

TOTAL CONTROL SOLUTIONS
 ELECTRONICS DIVISION, BANGALORE

maxNET Communications Network

Proven Industry Standard, Switched Fast Ethernet

Ultra high speed (100 Mbps) redundant network
Multiple simultaneous communication
Utilises intelligent switching
No collisions occur. Traffic is never stopped

CE/MKTG/EDN : July 2007

TOTAL CONTROL SOLUTIONS
 ELECTRONICS DIVISION, BANGALORE

Inter-Hub Communications
Full Duplex Switched Hub Full Duplex Switched Hub

100 Megabits per Second

Full Duplex

All standard communication media supported -

Fiber optic and UTP

Future Gigabit and high communications rates

CE/MKTG/EDN : July 2007

TOTAL CONTROL SOLUTIONS
 ELECTRONICS DIVISION, BANGALORE

Network Failover
Switch A
Network A
Network MAP
from Station 1
1 2 3
Station A B
2 OK OK
3 X OK
Network B
Switch B

WorkStation 1 hears messages from station 2 on networks A and B.

WorkStation 1 hears messages from station 3 only on network B.
WorkStation 1 knows that it can talk to station 2 on either network A or
B, but it must use network B to talk to station 3.
WorkStation 1 generates an alarm to notify the Operator.
Network B is used for messages

CE/MKTG/EDN : July 2007

TOTAL CONTROL SOLUTIONS
 ELECTRONICS DIVISION, BANGALORE

Network Domains
maxSTATIONS maxSTATIONS

Switched
Hub

RPUs RPU
maxSERVER
Global access of data for data acquisition and control
Separates discrete sections of DCS - e.g. plant units
Provides security and assures performance
Simplifies maintenance
Allows integration of other systems

CE/MKTG/EDN : July 2007

TOTAL CONTROL SOLUTIONS