PLC

&
DDCMIS

What is PLC?
Programmable
Logic
Controller
a nice replacement
for electromechanical
relay controls

What is PLC?
A PLC is an industrially hardened computerbased unit that performs discrete or
continuous control functions in a variety of
processing plant and factory environments.
Originally intended as relay replacement
equipment for the automotive industry, the
PLC can be found in some part of virtually
every type of industry imaginable.
The primary reason for designing such a
device was eliminating the large cost
involved in replacing the complicated relay
based machine control systems.

What is inside a PLC?

PROGRAMMING
DEVICE

POWER SUPPLY

CPU

MEMORY

I/O BUS
I/O SYSTEM MODULES

OUTPUT
DEVICES

SOLENOIDS
MOTOR STARTERS
ETC

INPUT
DEVICES

SWITCHES
PUSH BUTTONS
ETC

What is inside a PLC?

Power Supply
It converts Power Line voltages to those required by electronic
components of PLC.
It may be Integral or separately mounted.
It provides the isolation necessary to protect electronic components
from most high-voltage line spikes.
It is rated for heat dissipation requirements for plant floor operation.

What is inside a PLC?

Input Systems
Inputs are defined as real-world signals giving the controller real-time
status of process variables.
These signals can be analog or digital, low or high frequency,
maintained or momentary.
They are presented as a varying voltage, current or resistance value.
Signals from thermocouples and RTDs are common examples of
analog signals.
Pushbuttons, limit switches & electromechanical relay contacts are
familiar examples of digital, contact closure type signals.

What is inside a PLC?

Outputs

There are three common categories of outputs:

Discreet: Pilot lights, solenoid valves, annunciator windows (lamp

box)

Register: Panel meters or displays

Analog: Variable speed drives or I/P converters (control valves)

Most I/O systems are modular in nature; that is, a system can be arranged
by use of modules that contain multiples of I/O points.These modules can
be composed of 1, 4, 8, or 16 points and plug into the existing bus
structure.

The bus structure is really a high-speed multiplexer that carries

information back and forth between the I/O modules and the CPU.

One of the important functions of I/O is its ability to isolate real-world

signals from the low signal levels in the I/O bus

What is inside a PLC?

Central Processor Unit
It performs the tasks necessary to fulfill the PLC function. Among
these tasks are
Scanning
I/O bus traffic control
Program execution
Peripheral & external device communications
Self Diagnostics
One important factor which rates a PLC is scan time. It is roughly
defined as the time it takes for the PLC to interrogate the input
devices, execute the application program and provide updated signals
to the output devices.

What is inside a PLC?

Memory Unit
It is the library where the application program is stored.

It is also where the PLCs executive program is stored. An executive

program functions as the operating system of the PLC. It is the
program that interprets, manages and executes the users application
program.
It is the part of PLC where process data from the input modules and
control data for the output modules are temporarily stored as data
tables.
Memory can be volatile or nonvolatile. Volatile memory is erased if
power is removed. Battery backup is provided for most units with
volatile memory to avoid loss of program in the event of power outage.

What is inside a PLC?

Programmer Unit
It provides an interface between the PLC and the user during
program development, start-up and troubleshooting.
The instructions to be performed during each scan are coded and
inserted into memory with the programmer.
Programmers vary from small hand-held units the size of a large
calculator to desktop stand-alone intelligent CRT-based units.
Programmers come complete with documentation, reproduction, I/O
status & on-line and off-line programming ability.
Many PLC use a PC as the programming tool using the serial
interface and a Programming Software.

How a PLC Operates?

Step 1-CHECK INPUT STATUS-First the PLC
takes a look at each input to determine if it is
on or off. It records this data into its memory to
be used during the next step.
Step 2-EXECUTE PROGRAM-Next the PLC
executes your program one instruction at a
time using the input data obtained in previous
step and decides about the states of output. It
will store the execution results for use later
during the next step.
Step 3-UPDATE OUTPUT STATUS-Finally the PLC updates the
status of the outputs using the results obtained in previous step.
After the third step the PLC goes back to step one and repeats the
steps continuously.

How a PLC is Programmed?

Ladder Diagrams
Ladder diagrams are one traditional method of describing control
circuits.
There are a few basic symbols that are used to express the meaning
and purpose of a control circuits. They are
Normally Open
Contact

Starter/Relay/
Solenoid Coil

Normally Closed
Contact

Time Delayed
Contact

Normally Open
Push Button
Normally Closed
Push Button

(T.O.)
(Time to Open)

Example PLC Program

Let us consider a simple example. In the
given circuit, the coil will be energized
when there is a closed loop between the +
and - terminals of the battery(When both
the switches SW1 & SW2 are closed).
This simple circuit is represented in a
ladder Diagram as below.
A ladder diagram consists of

Some PLC require that every

ladder diagram include an END
instruction on the last rung.

individual rungs just like on a real

ladder. Each rung must contain one
or more inputs and one or more
outputs. The first instruction on a
rung must always be an input
instruction and the last instruction on
a rung should always be an output
(or its equivalent).

Advantages of PLC
Compared with electromechanical relay systems, PLCs offer the
following advantages:
Ease of programming and reprogramming in the plant.
A programming language that is based on relay wiring symbols
familiar to most plant personnel
High reliability and minimal maintenance

Small physical size

Ability to communicate with computer systems in the plant
Moderate to low initial investment cost

Rugged construction
Modular design

PLC Applications at Our Project

Some of the areas using PLC are:
Coal Handling Plant Stage-II
Ash Handling Plant Stage-II
DM Water Plant Stage-II
Condenser Tube Cleaning System Stage-II
Generator Stator Water Conductivity/Flow Protections Stage-I
Boiler Feed Pump Delta-T Protection in Unit-II

WHAT IS DDCMIS ?
DISTRIBUTED
DIGITAL
CONTROL,
MONITORING &
INFORMATION
SYSTEM

Distributed means there is no

centralized control and control
is spread across multiple units
Digital means processing of
process information is done in
digital form using microprocessor based hardware
MIS interfaces the human with
process using computers

DDCMIS TECHNOLOGICAL
BACKGROUND
PROGRESS OF INSTRUMENTATION USED TO IMPLEMENT
AUTOMATIC PROCESS CONTROL

LOCAL PNEUMATIC CONTROLLERS

MINIATURIZED AND CENTRALIZED PNEUMATIC

CONTROLLERS AT CONTROL PANELS AND CONSOLES

SOLID-STATE CONTROLLERS

COMPUTERISED CONTROLS (SUPERVISORY)

DIRECT DIGITAL CONTROL(DDC)

DISTRIBUTED MICROPROCESSOR BASED CONTROL

Why DDCMIS?
Disadvantages of earlier Systems
Analog instrument panels required huge space, lot of
wiring and are less user friendly for monitoring of large
number of parameters.
Accuracy obtained with solid-state controls is not good and
they tend to drift with time.
Supervisory controls are inflexible as changing of control
configuration requires change in routing of wires.
Use of centralized control leads to complete failure during
shutdowns.

Components of DDCMIS
MAN MACHINE INTERFACE & PROCESS
INFORMATION SYSTEM

DATA COMMUNICATION SYSTEM

( DATA HIGHWAY)

CONTROL SYSTEM

Components of DDCMIS
DATA COMMUNICATION SYSTEM
LOCAL SYSTEM BUS It is just lines on the backplane of
control panel to which all the modules are connected directly. It
serves as communication medium between the modules.

INTRAPLANT BUS(IPB) It is a coaxial cable which runs

through all the panels of control system and interconnects
them.

LOCAL AREA NETWORK(LAN) It is a network of

computers which are connected to a single point(HUB).
SOME FORM OF REDUNDANCY IS PRESENT

Components of DDCMIS
CONTROL SYSTEM
FUNCTIONAL DIVISION
SG-C&I SYSTEM
TG-C&I SYSTEM
BOP-C&I SYSTEM
HARDWARE COMPONENTS
POWER SUPPLY

CONTROL PANEL
ELECTRONIC MODULES

SG-C&I SYSTEM
CONSISTS OF
BURNER MANAGEMENT SYSTEM (BMS)
SOOT BLOWER CONTROL SYSTEM (SBC)
SECONDARY AIR DAMPER CONTROL SYSTEM (SADC)
AUXILIARY PRDS CONTROLS (APRDS)
HP BYPASS SYSTEM(HPBP)

TG-C&I SYSTEM
CONSISTS OF
ELECTRONIC TURBINE PROTECTION (ETP)
AUTOMATIC TURBINE RUN-UP SYSTEM (ATRS)
AUTOMATIC TURBINE TESTING SYSTEM (ATT)
ELECTRO- HYDRAULIC TURBINE CONTROL SYSTEM (EHTC)
TURBINE STRESS CONTROL SYSTEM (TSC)
LP BYPASS SYSTEM (LPBP)
GLAND STEAM PRESSURE CONTROL
GENERATOR AUXILIARY MONITORING PANEL (GAMP)

BOP-C&I SYSTEM
CONSISTS OF OPEN LOOP CONTROL SYSTEM (OLCS) AND
CLOSED LOOP CONTROL SYSTEM (CLCS)
OLCS - THE SEQUENCE CONTROL, INTERLOCK OF ALL THE
PLANT SYSTEMS WHICH ARE NOT COVERED IN THE SG-C&I AND
TG-C&I. THIS INCLUDES MAJOR AUXILIARIES LIKE FD/ID/PA
FANS, AIR-PREHEATER, BFP/CEP/CWP/ BCWP , DMCWP/CLCWP
AND ELECTRICAL BREAKERS.
CLCS - THE MODULATING CONTROL FOR VARIOUS IMPORTANT
PLANT PARAMETERS, LIKE FW FLOW (DRUM LEVEL), FURNACE
DRAFT, COMBUSTION CONTROL (FUEL FLOW AND AIR FLOW), PA
HDR PRESSURE CONTROL, DEAERATOR/HOTWELL/HEATER
LEVEL CONTROLS ETC.

CONTROL SYSTEM - HARDWARE

THE CONTROL SYSTEM USED IN STAGE-II IS

PROCONTROL P13/42
PROCONTROL MODULES
INPUT
OUTPUT
PROCESSOR
DRIVE
BUS COMMUNICATION

CONTROL SYSTEM - HARDWARE

INPUT MODULE
It receives the process signal, convert them to digital form and
communicate the value on local bus
ANALOG
Voltage(EA01) 4-channel
Current(EA02) 4-channel
RTD(EA03) 4-channel
Thermocouple(EA04) 8-channel

DIGITAL
Voltage(EB01) 4-channel
Single contact(EB02) 16-channel
Change-over contact(EB03) 5-channel

CONTROL SYSTEM - HARDWARE

OUTPUT MODULES
They receive the value from localbus and give output to the
process/field.

ANALOG
Voltage(AA01) 4-channel
Current(AA02) 4-channel
DIGITAL
Voltage(AB01) 16-channel
Contact(AB02) 16-channel

CONTROL SYSTEM - HARDWARE

PROCESSOR MODULE ( PR05)
IT IS RESPONSIBLE FOR THE EXECUTION OF ALL THE
LOGICS THAT IS PROGRAMMED INTO IT
IT CAN BE USED IN REDUNDANT MODE
IT IS PROGRAMMED USING SK06 KIT, WHICH IS A
COMPUTER BASED UNIT FOR INTERFACING WITH
PROCESSOR
THE LOGICS ARE PROGRAMMED USING THE P10
LANGUAGE

CONTROL SYSTEM - HARDWARE

DRIVE MODULES
THESE ARE USED FOR CONTROLLING THE DIFFERENT
TYPES OF PROCESS ACTUATING ELEMENTS
THEY HAVE PREDEFINED LOGICS BUILT INTO THEM
TYPES
ANALOG (AS06)
USED FOR DRIVING ANALOG CONTROL DRIVES SUCH AS
VARIABLE SPEED DRIVES, CONTROL VALVES THROUGH
I/P CONVERTER ETC
DIGITAL (AS04)
USED FOR OPERATING MOTORS, ELECTRICAL VALVES,
SOLENOID VALVES ETC

CONTROL SYSTEM - HARDWARE

BUS/COMMUNICATION MODULES
BUS TRAFFIC DIRECTOR
IT CONTROLS THE COMMUNICATION PROCESS ON THE
BUS
- THERE ARE TWO TYPES OF TRAFFIC DIRECTORS:
LOCAL BUS(BV05)
INTRAPLANT BUS(FV05)

BUS COUPLER(BK02)
IT CONNECTS THE LOCAL BUS TO THE IPB
BUS END MODULE(BA01)
IT IS USED FOR TERMINATING THE LOCAL BUS

LOCAL BUS P42

IPB

Analog
Input
Module

Binary
Input
Module

PROCESSOR

Local Bus

Bus
Coupler

AD
Analog
Output
Module

Binary
Output
Module

DRIVE
CONTROL
MODULE

CLK

LOCAL
BUS
TRAFFIC
DIRECTOR

CONTROL SYSTEM OVERVIEW

IPB - 1

IPB
TRAFFIC
DIRECTOR

BUS
COUPLER

BUS
COUPLER
Local Bus
-1.0C,2.0C

Local Bus -1.0B

BUS
COUPLER
IPB - 2

IPB
TRAFFIC
DIRECTOR

WSPOSE
PANEL

BK 02
Local Bus -1.0C

SERVER

Components of DDCMIS
MMIPIS MAN MACHINE INTERFACE & PLANT INFORMATION
SYSTEM
Functions

VPC OPERATION
OTHER OPERATOR INFORMATIONS THROUGH VARIOUS
DISPLAYS
ALARMS, LOGS, HISTORICAL AND LONG TERM STORAGE.
PERFORMANCE AND OTHER CALCULATIONS

PMS AND WSPOSE ARE EXAMPLES OF MMIPIS SYSTEM

WSPOSE OVERALL VIEW

PS

PS

PR

PR05

O/P
LOCAL BUS STATIONS

I /P

I /P

O/P

I /P

BK

I /P

O/P

BK
IPB 1 & 2

WS POSE PANEL ( DDC MMI INTERFACE PANEL )

SERVER 1

SERVER 2

LAN
OWS 1

OWS 5

OWS -1

OWS -2

OWS -3

OWS -4

WORKSTATIONS
PMS PANEL
LAN
SERVER2

SERVER1
IPB
ACCESS
COUPLER

PMS
SYSTEM

STATION
C&I

SG PACKAGE TG PACKAGE
IPB - 1
IPB - 2
IPB - 3
IPB - 4

WHY DDCMIS ?
1. VERY HIGH FLEXIBILITY FOR MODIFICATION
IN CONTROL STRATEGY
2. VERY HIGH SELF-DIAGNOSTIC
3. VERY LOW DRIFT (ONLY IN I/O CARDS) , HENCE
NO NEED OF FREQUENT RE-CALIBRATION
4. MUCH HIGHER RELIABILITY (BASED ON MTBF)
5. BETTER LONG TERM SUPPORT DUE TO
CHANGING TECHNOLOGY
6. MUCH BETTER OPERATOR INTERFACE

PLC & DDC - COMPARISION

DCS systems are used for large applications and closed loop
controls, whereas, PLC are primarily used for small applications
and sequential controls.
DCS systems are very costly for small applications, whereas,
PLCs are much cost-effective for both small and large
applications.
While DCS systems are superior in communication redundancy
and data security, PLCs are better for logic, are faster and have
more rugged I/O.

DCS systems are more difficult to design than PLCs.

SALIENT FEATURES OF
DDCMIS

SALIENT FEATURES OF DDCMIS

INTEGRATED PLANT CONTROL FOR SG,
TG AND BALANCE OF PLANT CONTROL
IT MAY BE REMEMBERED THAT HISTORICALLY
THE TERM DDCMIS USED BE REFERRED TO FOR
THE SO-CALLED BOP-C&I . THE SG-C&I, i.e. FSSS
etc. TG-C&I i.e. ATRS, TURBINE PROTECTION etc.
ORIGINALLY WERE NOT CONSIDERED UNDER
DDCMIS OR DCS AS PER MANY SUPPLIERS. ONLY
RECENTLY THE TYPE OF SYSTEMS FOR ALL THE
SYSTEMS HAVE BECOME SIMILAR (WITH SOME
DIFFERENCE WHICH WILL BE DISCUSSED LATER),
WE TEND TO CONSIDER THESE SYSTEMS UNDER
DDCMIS.

SALIENT FEATURES OF DDCMIS

INTEGRATED PLANT OPERATION
THROUGH FULLY INTERCHANGEABLE
OPERTAOR WORK STATIONS (OWS) FOR
SG, TG AND BALANCE OF PLANT
(SOMETIMES THIS MAY NOT BE POSSIBLE DUE TO
PACKAGING CONCEPT)

SALIENT FEATURES OF DDCMIS

PROVISION OF EXTENSIVE SELFDIAGNOSTICS
USE OF LARGE VIDEO SCREENS FOR
PROJECTIONS OF VARIOUS PLANT
MIMICS ETC.
PROVISION OF FAULT ALARM
ANALYSIS TO GUIDE THE OPERATOR TO
THE MOST LIKELY EVENT
PROVISION OF TREND ALARMS

SALIENT FEATURES OF DDCMIS

PROVISION OF SAFETY HARDWARE FOR
BURNER MANAGEMENT SYSTEMS
PROVISION OF FAIL-SAFE HARDWARE
FOR TURBINE PROTECTION SYSTEM
PROVISION OF ADEQUATE RELIABILITY
AND AVAILABILITY WITH PROPER
REDUNDANCY IN SENSOR, I/O AND
CONTROLLER LEVELS.

DDCMIS CONFIGURATION
maxDNA
SYSTEM
ENGG. STN
FOR HMI

HMI

PROCONTROL
SYSTEM

MMI LAN
HMI
REDUNDANT
SERVERS

ENGG.STN.
FOR CONTROL SYS.

I.P. BUS Max. 4

nos. rdundant
Redundant
F.G.Controllers

Measurement system / I/O

subsystem

CONTROL SYSTEM

CONTROL SYSTEM
PROGRAMMING &
CONFIGURATION

MMIPIS
SYSTEM

M&S
CLOCK

DCS

SG- C&I
SYSTEM

BOP- C&I
SYSTEM

TG- C&I
SYSTEM

DCS

2 X 100 %
CONTROLLERS
(INCL. COMM. CONT.)

LOCAL BUS

I/O CARDS

DCMS **

FUNCTIONAL GROUPS
SIGNIFICANT REDUCTION IN
NUMBERS EXPECTED IN
FORTHCOMING PROJECTS
COMBINING OF OLCS AND CLCS
CONTROLLERS - HISTORICAL
BACKGROUND
EXCEPT FOR CERTAIN SUPPLIERS,
ALL HAVE VERY POWERFUL
CONTROLLERS

TRANSPARENCY 6,7,8 FOR GROUP DRAWINGS

MMIPIS

MAN-MACHINE INTERFACE AND

PLANT INFORMATION SYSTEM
LATEST STATE-OF-THE-ART WORKSTATIONS
AND SERVERS BASED ON OPEN-ARCHITECTURE
AND INDUSTRY STANDARD HARDWARE AND
SOFTWARE TO ENSURE BETTER CONNECTIVITY.
e.g. HARDWARE FROM COMPAQ/DIGITAL, HP,
SUN MICRO-SYSTEM OR OTHER MAJOR
SUPPLIERS (LESS DEPENDENCE ON THE C&I
SYSTEM SUPPLIER IN THE LONG RUN)
OPERATING SYSTEM WINDOWS-NT, OPEN-VMS
OR UNIX.

MAN-MACHINE INTERFACE AND

PLANT INFORMATION SYSTEM
64-BIT SERVER/OWS WITH HIGH-SPEED
AND LARGE MEMORY (256/512 MB RAM, 8
GB HDD FOR SERVER AND 128/256 MB RAM
AND 4/6 GB HDD FOR OWS) TO ENSURE
FAST RESPONSE
PROVISION OF LVS
CONNECTION TO OTHER SYSTEM
THROUGH STATIONWIDE WAN

TRANSPARENCY NO 9 & 10

MMIPIS FUNCTIONALITIES
VPC OPERATION
OTHER OPERATOR INFORMATIONS
THROUGH VARIOUS DISPLAYS
ALARMS, LOGS, HISTORICAL AND
LONG TERM STORAGE.
PERFORMANCE AND OTHER
CALCULATIONS

DCS

REDUNDANT DATA
COMMUNICATION SYSTEM (DCS)
1. MAIN SYSTEM BUS
2. LOCAL SYSTEM BUS

3. LOCAL BUS OR I/O BUS

4. OWS LAN

5. STATION-WIDE WAN

DDCMIS CONFIGURATION
maxDNA
SYSTEM
ENGG. STN
FOR HMI

HMI

PROCONTROL
SYSTEM

MMI LAN
HMI
REDUNDANT
SERVERS

ENGG.STN.
FOR CONTROL SYS.

I.P. BUS Max. 4

nos. rdundant
Redundant
F.G.Controllers

Measurement system / I/O

subsystem

OFF-LINE LAN

GATEWAY
STATION-WIDE

UNIT C&I
SYSTEM
(TYP)

OTHER
UNITS

TO CORP.
CENTRE
ON-LINE LAN

OFF-SITE C&I
SYSTEM
(TYP)

POWER SUPPLY SYSTEM

CONTROL SYSTEM POWER SUPPLY TWO SETS
OF DC POWER SUPPLIES - ONE SET FOR SG/TGC&I AND OTHER FOR BOP-C&I EACH WITH 2 X
100 % CHARGER AND 2 X 100 % BATTERY.
OTHER IMPORTANT AC LOADS LIKE MMIPIS,
PANEL INSTRUMENTS, ANALYSERS ETC.
SHALL BE POWERED FROM UPS COMPRISING
OF 2 X 100 % CHARGER, 2 X 100 % INVERTER
AND 1 X 100 % BATTERY.
HEAVY DUTY Ni-Cd BATTERIES HAVE BEEN
ENVISAGED FOR LONGER LIFE & LESSER
MAINTENANCE

CABLING & TERMINATION

EXTENSIVE GROUPING OF SIGNALS BY LARGE
SCALE USE OF JBs AT STRATEGIC LOCATIONS

USE OF CABLES WITH HIGHER NO OF PAIRS

USE OF MAXI-TERMI CONNECTION FOR
SYSTEM CABINETS, MARSHALLING PANELS &
OUTGOING SIDE OF JBs, CJS BOXES etc.
USE OF PLUG-IN SOCKET AND CONNECTORS
FOR TRANSMITTERS, SWITCHES, LS/TS etc.

IMPORTANT SG/TG RELATED C&I SYSTEM

FLAME MONITORING SYSTEM

COAL FEEDER C&I
ELECTROMATIC SAFETY VALVES
FURNACE TEMP PROBES
ACCOUSTIC PYROMETER FOR FURNACE TEMP PROFILE
BOILER FLAME ANALYSIS SYSTEM
COAL BUNKER LEVEL MONITORING SYSTEM
ELECTRONIC DRUM/SEPARATOR LEVEL MONITORING
SYSTEM
TURBINE SUPERVISORY SYSTEM
TDBFP TURBINE SUPERVISORY SYSTEM

IN PACKAGED SYSTEM, THESE ARE

UNDER SG & TG PACKAGES.

SCOPE OF SUPPLY OF C&I SYSTEM

DDCMIS (IN C&I PACKAGE, SG-TG C&I & ASSOCIATED

MMI etc. EXCLUDED)
OTHER SG/TG C&I (ONLY FOR TURN-KEY PACKAGE)
MEASURING INSTRUMENTS
SWAS
CONTROL DESK/PANELS
ALARM ANNUNCIATION
ELECTRIC POWER SUPPLY
CONTROL VALVE AND ACTUATORS (ONLY FOR 500 MW
PROJECTS, BEING DELETED FROM C&I IN RECENT
PROJECTS)
MAINTENANCE & CALIBRATION EQUIPMENT
INSTRUMENTATION CABLES
PROCESS CONNECTION & PIPING
PA SYSTEM
OFF-SITE PLANT CONTROL SYSTEM (ONLY FOR TURNKEY PACKAGE, ELSE IN RESPECTIVE MECH. PKG)

OPERATION PHILOSOPHY
CENTRALISED OPERATION OF MAIN PLANT THROUGH
OWS & LVS
OFF-SITE PLANTS TO BE CONTROLLED FROM THEIR
LOCAL STATIONS WITH STATION-WIDE LAN DATA LINK
MINIMUM BACKUP INSTRUMENTATION ( ORIGINALLY
CONSERVATIVE, NOW REDUCED. CRITERIA - HANDLING
EMERGENCY & SAFE SHUT-DOWN)
GEOGRAPHICAL DISTRIBUTION - ALTHOUGH NOT VERY
USEFUL FOR POWER PLANTS AS COMPARED TO
PROCESS/INDUSTRIES, BEING ADOPTED FOR FEW AREAS
WHERE SIGNALS ARE CONCENTRATED (REDUCTION OF
CABLING, MUCH LESS ERECTION & COMMISSIONING
TIME)

REDUNDANCY
IN CONTROL SYSTEM

ORIGINALLY THE CONTROLLERS

ALT-I - SINGLE LOOP NON-RED
ALT-II- MULTI-LOOP REDUNDANT

NOW ALT-I ABOLISHED.NOW 2 X 100 % OR 2 OUT OF 3.

I/O REDUNDANCY - CURRENT PROJECTS HAVE HIGH

LEVEL OF I/O & DRIVE CONTROL MODULES
REDUNDANCY DUE TO LOWERING OF BACK-UP AND
INCREASE IN NO. OF CHANNELS. IN FUTURE PROJECTS,
LIMITED TO SAFETY SYSTEMS AND CASES WHERE
SENSOR REDUNDANCY IS THERE.
DATA COMMUNICATION SYSTEM - 100 % REDUNDANT
MMIPIS
- REDUNDANT SERVERS
MULTIPLE OWS (PRESENTLY 10 NOS, BEING REDUCED TO 6 NOS.)

DESIGN CRITERIA
PROVENNESS
SUPPLIERS EXPERIENCE
SYSTEM EXPERIENCE
PROVENNESS VS OBSOLESCENCE

RELIABILITY AVAILABILITY

HARDWARE QUALITY (PUBLISHED MTBF etc.)

CONFIGURATION
REDUNDANCY
FAULT TOLERANCE

STANDARDISATION AND UNIFORMITY OF H/W

SAME SERIES & FAMILY OF H/W AS FAR AS POSSIBLE
DIFFICULTIES BECAUSE OF PACKAGING CONCEPTS &
RESPOSIBILITY CENTRE & INTERFACES (EVEN IN TURNKEY
PACKAGE)

DESIGN CRITERIA
OPERABILITY
DESIGN CONCEPT - FAIL SAFE ETC.
FALSE TRIP VS SAFETY
OPERATOR CONVENIENCE DURING NORMAL RUNNING &
EMERGENCY
MANAGEMENT REPORTING

MAINTAINBILITY

STANDARDISATION (AS INDICATED ABOVE)

MODULAR DESIGN AND EXPANDABILITY
DIAGNOSTIC, FAULT IDENTIFICATION AND FAULT TOLERANCE
GUARD AGAINST OBSOLESCENCE
AVAILABILTY OF SPARES

OTHER CRITERIA
UNIT OPERATION PHILOSOPHY
MARKET TRENDS AND EVOLUTION OF INFORMATION
TECHNOLOGY
FEEDBACKS FROM EXISTING SYSTEMS