TW/6?

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REV. NO. OO

Write-up on $G Package{maxDNA}
A4

PAGE 01 OF 07

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TWl676l4rOlrLT
Write-up on SG Pnckage(maxDNA)

RtrV NO.OO
A4

PAGE 02 OF 07

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TW/676/410/117

Write-up on SG Package (maxDNA)

REV NO. 00
A4 - 12

PAGE 03 OF 07

The system configuration is drawn based on tender specification, BHEL offer and BHELTRICHY and BHEL-PEM basic diagrams (inputs) and in line with the implementation followed for
various Captive and Utility Power Plants.

COPY RIGHT AND CONFIDENTIAL

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

Each of the sub system is functionally distributed with reference to all the hardware
associated with these controls. The controls covered under the scope of supply are

Furnace Safeguard Supervisory System (FSSS)

Secondary Air Damper Controls (SADC)
Auxliary Pressure Reducing and De-super heating system (APRDS)
Soot Blower Controls (SBC)
HP Bypass system (HPBP)

The control & monitoring system for Steam Generator is build around maxDNA, a
microprocessor based Distributed Digital Control System. RPUs (Remote Processing Units) are the
functional islands engineered in parallel and shared I/O configuration except for MFT which is
configured in 3 RPUs with 3 nos of single DPUs (Processor).
The total control system, housed in several suits of cabinets as per OGA of cubicle ,
365900 0089,which are though installed in a geographically centralised location but engineered in
functionally, distributed architecture. Accordingly each RPU or suit provides its associated field
cable terminations in separate compartment of the same suit.
MaxNET communication system, having physically separate two sets of cables & switches,
operating on Switched Fast Ethernet Standard, interconnects all the RPUs and HMI (Human
Machine Interface) provides redundant data highway for transfer of data such as drive statuses /
permissive / trip conditions among one another.
The RPU and DPU allocations are as per Table below.
RPU Function
DPU
Function
FSSS
MFT
1x3Single
Boiler protection in 2 of 3 mode
Purge
1 Pair
Common function like Purge, SADC etc.
Oil AB
1 Pair
Control &interlocks of Oil elevation
AB- LO and HO
Oil CD & EF
1 Pair
Control &interlocks of Oil elevation
CD- HO and Oil elevation EF- HO
OIL GH
1 Pair
Control &interlocks of Oil elevation
GH- HO
COAL A & B
1 Pair
Control &interlocks of Coal elev.A&B
COAL C & D
1 Pair
Control &interlocks of Coal elev.C&D
COAL E & F
1 Pair
Control &interlocks of Coal elev.E&F
COAL G & H
1 Pair
Control &interlocks of Coal elev.G&H
SADC / APRDS
1 Pair
SADC analog controls, Control &
interlocks of APRDS.
SBC
1 Pair
Soot Blower Operation & Interlocks.
HPBP
1 Pair
Control & interlocks of HPBypass
system.
Each of these functions is described below.

TW/676/410/117

REV NO. 00

Write-up on SG Package (maxDNA)

PAGE 04 OF 07

COPY RIGHT AND CONFIDENTIAL

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

A4 - 12

Furnace Safeguard Supervisory System (FSSS) is distributed functionally to various RPUs,

which are
Master Fuel Trip (MFT) / Boiler Protection
Purge and Unit common logics
Oil elevation controls
Coal elevation controls

FIG 1:REALISATION OF MFT

LINE B

Redundant network

LINE A

MFT1 RPU

MFT2 RPU

MFT3 RPU

D
P
U

D
P
U

IO BUS

I
P
M
O
D

D
P
U

IO BUS

I
P
M
O
D

I
P
M
O
D

O
P
M
O
D

I
P
M
O
D

IO BUS

I
P
M
O
D

KA

I
P
M
O
D

O
P
M
O
D

I
P
M
O
D

I
P
M
O
D

KB

KC

+24 V
S1

S2

EMERGENCY PB

S3

HARDWIRED MFT FOR FUEL CUTOFF DRIVES

KA
KB

TRIPLICATE TRIP
INPUT (TYPICAL)
S1, S2, S3 ARE
CONTACTS OF THE
SIGNAL

KB

KC

KC

KA

O
P
M
O
D

KA, KB, KC ARE SET

OF CONTACTORS
FOR GENERATION
OF MFT

TW/676/410/117

REV NO.00

Write-up on SG Package (maxDNA)

PAGE 05 OF 07

COPY RIGHT AND CONFIDENTIAL

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

A4 - 12

Master Fuel Trip (MFT) is configured in 2 out of three mode. The configuration of MFT
is as per FIG 1. Triplicate inputs are acquired in 3 independent modules in 3 channel MFT RPUs.
Based on 2 out 3 voting logic and depending on the system requirement identical programs run in
DPUs of the 3 channels. The generation of output in each of the channels is available in
redundant network, which will be used with 2 out of 3 voting in other RPUs like Oil and coal etc.
In addition to this for fuel cut-off drives (LOTV, LONV, HOTV,HONV,Feeder, Hot Air Gate,
Pulveriser) to drive to safe position hardwired back up is envisaged with the use combinational
relay logic, which will ensure total fuel cut off.
Triplicate inputs of the field are acquired in three channels of the independent modules.
The field inputs are connected in parallel to each of the channels. The discrepancies in actuation
associated with these inputs are monitored and annunciated in HMI. Single processor (DPU) is
being used in each of the channel, which will have software 2 out of 3 for generation of MFT.
Output module will generate the MFT, which are used to drive set of contactors. Based on this 2
out of 3 combinational logics are built to ensure hardware back up for Fuel cut off drives. For
Oil and Coal drive status required in logic realization of MFT the same is acquired through
maxNET.
The RPUs, which houses redundant DPUs in Purge, Oil and Coal logic realization these
signals of MFT, are used for realizing protection. Typical Fuel cut off drive realization is as per
fig 2 below. Equivalence of MFT generation is monitored in PURGE RPU and Alarm is generated
for non-equivalence.
To enhance the protection Emergency Push Button is wired directly to MFT contactors,
which will generate hardwired MFT irrespective of the RPUS availability.

DRIVE POWER SUPPLY

HARDWARE (2/ 3 MFT)

OPEN

CLOSE
FINAL CONTROL
ELEMENT

FIG 2. IMPLEMENTATION OF FUEL CUT OFF DRIVE

TW/676/410/117

Write-up on SG Package (maxDNA)

COPY RIGHT AND CONFIDENTIAL

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

A4 - 10

REV NO. 00
PAGE 06 OF 07

Power supply Monitoring for MFT:

The system is powered by redundant dual feeder of 230 V AC UPS (from ACDB). The
Power required for System supply and for the field is provided through separate redundant
AC/DC converters mounted in the respective cabinets. This ensures isolation between system
supply and field supply.
The system and the interrogation supply to individual racks is distributed to the racks.
Each rack has a provision for accepting system power supply which is 24 V DC and interrogation
/ Transmitter power supply which is also 24V DC .The interrogation voltage is routed through the
input cards for powering the field instruments.
The Loss of 24 V DC is monitored with the help of 220 V DC contactors and 24 V DC
relays. Each of MFT RPUs are monitored and in the event of failure of 24 V DC to more than 2
MFT channel hardwired MFT is generated which will ensure Fuel cut off to the furnace and
Boiler trip.
Unit level drives operates on 220 V DC powers supply. 220 V DC is monitored with the
help of contactor. The contact generated from this for loss of 220 V DC is wired as input to all
the three protection channels, which will in turn is used as a MFT condition and generates MFT.
Corner level drives operates on 110 V AC. The 110 V AC at each elevation control panel is
monitored with the help of contactor .The contact generated on loss of 110 V AC is wired to
respective RPUs of the elevation controls. The logic associated with this will be realized in both
protection channels for generation of MFT and cut off fuel to the furnace.
With the above it is evident that loss of critical power in the FSSS is monitored and will
drive to fail safe mode of the boiler.

Secondary Air Damper Controls (SADC) & Aux.PRDS:

The functions of SADC for Fur WB DP controls, Fuel dampers controls and APRDS
functions are realized in Redundant DPUs and non-redundant Input and Output modules. Binary
logics of SADC are realized in Purge DPUs and software signal exchange is envisaged through
maxNET. No hardwired console is envisaged for SADC operations and APRDS operations as these
operations are provided in Operator Work Station ( OWS) as part of HMI Package.

Soot Blower Controls (SBC) :

SBC functions of manual operation (Enable / Disable / Start) and Sequence logics are
realized in this DPU. All operations of SBC are provided in Operator Work Station ( OWS) as
part of HMI Package and hence no hardwired console and mimic is envisaged for this function.

TW/676/410/117

Write-up on SG Package (maxDNA)

COPY RIGHT AND CONFIDENTIAL

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

A4 - 10

REV NO. 00
PAGE 07 OF 07

HP Bypass (HPBP):
The functions of HPBP are realized in redundant DPUs and non-redundant Input and
Output modules. BP valves are interfaced with Hardwired drive control module (DSZAB or
equivalent) to meet the requirement of valve positioning.
General:
Hardwired Console Operator Interface:
Console is envisaged for FSSS functions and HP Bypass functions as per system requirement.

Field interrogation voltage envisaged is 24 V DC.

Signal exchange between maxDNA SG and DDCMIS :

As per recommendation of system designer, signals required for trip and interlocks (both input
and output) are hardwired.

Redundancy

a.
Redundant processors are housed in separate racks .
b.
Redundant Output modules are provided for following critical fuel cut off drives such as
LOTV , HOTV , HONV , LONV ,Steam atomising and Air atomising valves , Pulverisor , Feeder
and Hot Air Gate.
c.
System power supply , interrogation power supply are all 1:1 redundant .
d.
Each DPU connects to the switches of Line A and Line B of maxDNA.
SADC &APRDS/ SBC/HPBP Systems
A. Processor: Dual redundant
B: Binary / Analog Inputs & Signal exchange Input : Non redundant
C: Binary /Analog Outputs: Redundant

Other applications like Alarms, Console, data acq and interface to other system are
non redundant. For further details on redundancy,System design philosophy document no.
415/MPCL/ 001 may be referred.