Sales

Sales Training
Training
Integration
Integration with
with turbine
turbine control
control systems
systems

For centralized monitoring & control of the whole plant

Presenter: Sambasivam, Hariharan (SN01)

http://web.iac.sea.honeywell.com/IS/OPCMark/default.asp

Confidential & Proprietary

Turbine Integration - Sales Training - May 2003

Agenda
Agenda

• GE turbines (OPCMark - using GE proprietary GSM protocol)

• Alstom/ABB turbines (OPCBridge - using OPC protocol)

• Need for integrating turbine control system with DCS

• Limitations of MODBUS & why use GSM or OPC protocol?

• Typical integration architecture with TPS or Experion

• Integration feature summary

• Product Technical Overview

• Opportunity Identification
• Beating Competition

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Turbine Integration - Sales Training - May 2003

1
 The
The need
need for
for integration
integration turbine
turbine controls
controls with
with DCS
DCS

Main DCS

MODBUS
TURBINE
CONTROL

New GSM / OPC

BOP

FUEL ELECTRICAL WATER, WASTE HEAT RECOVERY UTILITIES,

SYSTEMS DISTRIBUTION WATER STEAM THIRD-PARTY
SYSTEMS TREATMENT GENERATOR HRSG SYSTEMS

• Single window to entire plant process • Consolidation of alarms and events(SOE) in

one console
• Supervisory control functions
Start-up and shutdown sequences • Plant efficiency calculations
Speed & Load control
Automatic synchronization • HRSG and BOP control
Remote turbine alarm acknowledgment

Confidential & Proprietary

Turbine Integration - Sales Training - May 2003

Limitations
Limitations of
of MODBUS
MODBUS
MODBUS
MODBUS Vs
Vs GSM
GSM // OPC
OPC protocol
protocol

• MODBUS does not transmit alarm and event data (SOE) as they occur and hence turbine
SOE data were not available in DCS for consolidated supervision and analysis. GSM / OPC
supports alarm and event (SOE), a key need in power generation

• Turbine alarms at GE’s HMI server (or Alstom/ABB OPC server) acknowledged at DCS
console - MODBUS does not do this while GSM/OPC protocol supports this.

• Transmission rate - Serial comms has baud rate limitations (56Kb); Ethernet provides
high speed 10Mbaud rate. This particularly helps to transfer large throughputs i.e.1000-
2000 parameters / sec. Asynchronous data transmission helps this. No polling

• Master-slave: Only one MODBUS master can be talking to a MODBUS slave at any
instance. GSM/OPC is client-server and allows multiple hosts to access it
simultaneously. This helps in redundancy and load balancing.
• DCS serial ports: DCS should dedicate 2 serial ports (dual) for each turbine controller.
Thus, for 4 controllers, DCS would require 8 ports. Note: Daisy chaining would affect
transfer rates, hence not recommended. GSM/OPC is on Ethernet and hence not an issue.

• Scaling of decimal values to integers and re-conversion at receiving end results in loss
of accuracy. GSM/OPC transmits decimal values directly.

Confidential & Proprietary

Turbine Integration - Sales Training - May 2003

2
Typical
Typical turbine
turbine integration
integration architecture
architecture in
in TPS
TPS

Block 1 UDH B(Arcnet Block 2 UDH B(Arcnet

/Ethernet) /Ethernet)

GT1 GT2 ST1 GT3 GT4 ST2

UDH A(Arcnet UDH A(Arcnet

/Ethernet) GE / Alstom / ABB /Ethernet) GE / Alstom / ABB
turbine controllers turbine controllers

GE’s HMI GE’s HMI GE’s HMI GE’s HMI

server A server B server C server D

Alstom / ABB Alstom / ABB

OPC servers OPC servers

Dual Ethernet
OPCMark/OPCBridge OPCMark/OPCBridge
(Primary & Backup) (Primary & Backup)

APP node 1 (OPC server) APP node 2 (OPC server) APP node 3 (OPC server) APP node 4 (OPC server)

LCN (DCS)

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Turbine Integration - Sales Training - May 2003

Typical
Typical turbine
turbine integration
integration architecture
architecture in
in Experion
Experion

Block 1 UDH B(Arcnet Block 2 UDH B(Arcnet

/Ethernet) /Ethernet)

GT1 GT2 ST1 GT3 GT4 ST2

UDH A(Arcnet UDH A(Arcnet

/Ethernet) GE / Alstom / ABB /Ethernet) GE / Alstom / ABB
turbine controllers turbine controllers

GE’s HMI GE’s HMI GE’s HMI GE’s HMI

server A server B server C server D

Alstom / ABB Alstom / ABB

OPC servers OPC servers

Dual Ethernet
OPCMark/OPCBridge
(Primary & Backup)
Experion PKS
servers A/B

FTE

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Turbine Integration - Sales Training - May 2003

3
 Integration
Integration summary
summary

• Bi-directional integration between DCS and GE’s HMI server or Alstom/ABB

OPC server (e.g. GSM->DCS and DCS->GSM point mappings - analog and digital)

• OPCMark supports both Mark V and Mark VI type of GE turbine controllers

(GSM protocol is different)

• Integration of points from multiple turbine controllers through a common

HMI server

• Grouping of points for periodical data (different interval)

• Redundancy at multiple levels (OPC server, HMI server, Ethernet etc)

• Fetching alarm and event (SOE) data from turbine controllers and
consolidation at DCS (traditionally, trip contacts are duplicated to a separate SOE
instrumentation rack)

Confidential & Proprietary

Turbine Integration - Sales Training - May 2003

Integration
Integration summary
summary (continued…)
(continued…)

• Alarming in DCS when any controller or active HMI server/OPC server fails.
(Automatically switches over to the backup HMI/OPC server)

• Automatic detection of recovery of failed controller (avoids cumbersome

manual verification or re-registration process)

• Alarming in DCS when OPCMark or OPCBridge application itself fails. (The

partner OPCMark or OPCBridge takes over)

• Daily trouble-shooting logs - activity and error information

• User-friendly OPCMark/OPCBridge configuration tool with Excel

export/import

Confidential & Proprietary

Turbine Integration - Sales Training - May 2003

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Turbine
Turbine alarms
alarms and
and events
events (including
(including SOE)
SOE)

•Alarm Events (62 msec)
•Digital Input Events (1 msec - SOE)
•Software Events (62 msec)
Examples of events
• Changes in process alarm state.
• Changes in digital input (SOE card).
• Software detected changes in pre-
defined Boolean variables.
• Dead-band crossings detected in pre-
defined analog variables.
• Changes in controller alarm (diagnostic)
state.

Confidential & Proprietary

Turbine Integration - Sales Training - May 2003

OPCMark
OPCMark main
main screen
screen (for
(for GE
GE turbines)
turbines)

Guard House
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Turbine Integration - Sales Training - May 2003

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OPCBridge
OPCBridge main
main screen
screen (for
(for Alstom/ABB
Alstom/ABB turbines)
turbines)

Guard House
Confidential & Proprietary
Turbine Integration - Sales Training - May 2003

How
How does
does itit look
look in
in DCS?
DCS?

Area Alarm Summary OPCMark Operator

Process & Turbine graphics (Level 2)
Interface

H200

Control Point
Miscellaneous Turbine Load Control & Manipulation (Level 2)
Operator Work Area Process (Level 2)
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Turbine Integration - Sales Training - May 2003

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Turbine
Turbine Graphic
Graphic Templates
Templates

• Around 25 gas and 25 steam turbine graphics templates (GUS / HMIWeb)

replicated from GE or Alstom turbine graphics

•Gives a jumpstart in turbine graphic engineering rather starting from

scratch (quickens engineering time)

•Standardizes and maintains uniformity across various sites

•Modification work involves tag mapping, other minor functions

Confidential & Proprietary

Turbine Integration - Sales Training - May 2003

Current
Current OPCMark
OPCMark References
References

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Turbine Integration - Sales Training - May 2003

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Current
Current OPCBridge
OPCBridge References
References

Confidential & Proprietary

Turbine Integration - Sales Training - May 2003

Opportunity
Opportunity Identification
Identification

•Any site having or requiring power generation facilities

• Electric utilities
• IPPs (independent power producers)
• Co-generation needs in refineries and other HPI/chemicals plants
(Majority of our installed base has cogeneration needs)

•Role of DCS is greater in combined cycles due to complex processes

•New projects

•Retrofits and upgrades (obsolete technology, expansions etc)

•Alliances with turbine manufacturers ie. GE, Alstom and ABB, Siemens

•Awareness with EPC contractors (Chiyoda, Toyo, JGC, IHI, Samsung, Hyundai etc

Contractors, GE/ABB/ Alstom & end-customers have started insisting/specifying

GSM or OPC protocol based integration with DCS.

Confidential & Proprietary

Turbine Integration - Sales Training - May 2003

8
Existing
Existing Honeywell
Honeywell sites
sites using
using GE
GE turbines
turbines

Arizona Public Service Palo Verde 1,2,3 Oklahoma Gas&Electric Sooner 1,2
Basin Electric Power Coop. Laramie River 1,2,3 Pacific Power & Light Jim Bridger 1,2,3,4
Consumers Power Dan E. Karn 3,4 Pennsylvania Electric Conemaugh 1,2 1994
Cooperative Pwr Assoc. Coal Creek 1,2 Pennsylvania Power Mansfield 1,2,3 1993
Dayton Power & Light Stuart 1,2 Potomac Electric Chalk Point 3,4 1991
Florida Power Corp. Crystal River 12,4,5 Public Service Co. of NM San Juan 3,4
Florida Power Corp. Anclote 1,2 Public Service E & G Hope Creek 1 1994
Illinois Power Co. Baldwin 3 Salt River Project Navajo 1,2,3 1996
Iowa Power & Light Council Bluffs 3 San Antonio CPS Braunig 3 2001
Iowa Southern Util. Co. Ottumwa 1 Southern California Ed. Etiwanda 3, 4 2001
Kansas City Power & Light LaCygne 1,2 1995 Southwestern Pub Service Nichols 3
Kansas City Power & Light Iatan 1 Tampa Electric Big Bend 1,2,4
Louisville Gas & Electric Mill Creek 1,2,3,4 1997 Texas Utilities Elec Co. Lake Hubbard 2 1994
Mississippi Power & Light Gerald Andrus 1 Tri-State G&T Assn Inc. Craig 1,2,3 2001
Nebraska Pub Pwr Dist Gentleman 2 1996 Wisconsin Elec Pwr Co. Oak Creek 7,8
New England Power Brayton Point 1,2, 4 1994 Wisconsin Pwr & Light Columbia 2
Northeast Utilities Montville 6 Wisconsin Public Svc Pulliam 3,4,5,6,7,8 1990
Ohio Edison/Penn Power Mansfield 2,3,1
International Spain
Tata Electric, India Trombay 6 Empresa Nacional De Electricidad,S.A.
Almeria 1,2
Confidential
Puerto Rico&Water
Proprietary
Resources South Coast 1&2 Hidroelectrica Espanola S.A.Castellon 1&2
Turbine Integration - Sales Training - May 2003

Beating
Beating Competition
Competition

• Gives Honeywell a competitive edge in main DCS bidding

• Ready off the shelf , plug and play type interface

• Proven and standard product (reference list,

commendation letters)

• Standard product, hence lower cost than other DCS bidders and
annual product support (turbine integration is mission critical )

• Matrikon is the only known competitor providing a similar

functionality for GE (but lacks redundancy & cannot work directly with
TPS or Experion PKS - requires another middleware)

Confidential & Proprietary

Turbine Integration - Sales Training - May 2003

9
Contact
Contact

Sales & Technical Support: How we can help?

Technical Support,
Hariharan S Budgetary estimates,
Email : Sambasivam, Hariharan (SN01) Proposal generation,
Tel : 65- 6580 3376 (Singapore - GMT + 8 hours)
Customer presentations

Product information: http://web.iac.sea.honeywell.com/IS/OPCMark/default.asp

Thank You

Confidential & Proprietary

Turbine Integration - Sales Training - May 2003

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