Pms System Training

Agenda 1. Network Overview 4. Load Shedding Basics 3. Data Flow 2. Hardware Description 5. Misc. Functions

Network Overview Ethernet 3 Sets of Redundant Processors perform all PMS logic. Time Sync Processor Performs logging functions and Time Control HMI Servers and Clients Some Remote I/O chassis on “ S2” ControlNet Network Some Remote I/O chassis on “S1” ControlNet Network Some Remote I/O chassis on “ Fast” ControlNet Network All Processors on Separate “Processor” ControlNet Network Field devices connect serially. Gemstarts Serial to Ethernet Converters Breakers. Multilin and Micrologic MCP’s and ICSS and GCP’s

External Device Connection Example Remote Enclosure Multilin Serial to TCP Converter S1 CNET Fiber to Other Enclosure Fast CNET Fiber to Other Enclosure Ethernet Fiber to Other Enclosure Micrologic Serial to TCP Converter Gemstart Gemstart Gemstart SWG Control Panels Serial RS485 for Modbus Serial RS485 for Modbus Hardwire I/O DIRIS Hardwire I/O Including Load Shedding Signals Sync-Link Fiber to Other Enclosure S1 Rack Fast Rack

Network Protocol Information 1 Sync-Link Fiber (max 300m Typical <100m) Fiber (max 300m Typical <100m) Sync-Link 1 Ethernet/IP Modbus TCP TCP/IP HTTP Fiber Cat-5 Twisted pair Ethernet cable Ethernet Many Modbus RTU 2 wire shielded twisted pair 2 wire shielded twisted pair Serial 4 CIP over ControlNet Fiber (max 3000m Typical 300m) Coaxial shielded cable (max 1000m typical <100m) ControlNet Number of Networks Protocols Used by Network Media Outside Enclosure Media In Enclosure Network

Ethernet/IP BENEFITS Open industrial protocol utilizing standard TCP, UDP protocol Fast communication speeds 100Mbps. Uses well known networking technology (switches, routers, etc). Some devices can use web-server capabilities. Best Used for: Data Networks. E.g. HMI’s, data sharing between processors

ControlNet Benefits Scheduled Network (highly deterministic): Data is received when expected every time. Hardened media: Shielded Coaxial cable, Sturdy connectors, Industrial repeaters. Can be easily utilized as redundant I/O network Well supported for a ControlLogix application Best Used for: Fast I/O network, Time critical data between processors

Modbus TCP and RTU Modbus TCP Encapsulates Modbus protocol in standard TCP/IP protocol for transmission over Ethernet networks. Modbus RTU Serial Modbus protocol. Used at device level. Both networks are supported by Rockwell through third party devices. Prosoft Technology supplies modbus cards for ControlLogix racks.

Rockwell Supplied Application ControlLogix Platform Modular design means add I/O cards, processors, communication cards as needed. Very flexible. Same platform with proper peripherals can be used in almost any other control solution imagined. Programmed with Ladder Logic RSViewSE HMI Software for visualization and supervisory control Distributed application. Server coordinates data and stores HMI screens Clients request data and screens from server

Communication Devices Located in I/O Racks Prosoft Modbus RTU communication module. Allows ControlLogix racks to communicate with modbus RTU devices over RS485. 1756-MCMR Prosoft Modbus TCP communication module. Allows ControlLogix racks to communicate with Modbus TCP devices over Ethernet. 1756-MNETR Allen-Bradley Controlnet Redundant communication module. Allows ControlLogix racks to communicate over ControlNet protocol. Used in all remote racks and in main processor racks to control I/O. 1756-CNBR Allen-Bradley Ethernet Communication module. Allows ControlLogix racks to communicate over Ethernet via Ethernet/IP protocol. Used in main processor racks to share data and communicate with HMI. 1756-ENBT Description Device

Communication Hardware Continued Hirschmann Managed Ethernet Switch Provides redundant ring network setup Managed switch to configure each port if needed. Multinet Modbus converter Converts Modbus RTU to Modbus TCP Used to interface with serial Multilin devices from PC EGX modbus converter Converts Modbus RTU to Modbus TCP Used to interface with serial Micrologic devices from PC

Load Shedding Types Three Main Load Shedding Schemes Fast Acting Load Shed Drops enough load to make up for lost generation source. Very fast, < 120ms turnaround time in PMS system. User Configurable Priority Table Gradual Load Shed Sheds loads one at a time when Generator reserve capacity falls below a predefined level. User configurable. Underfrequency Shed Sheds loads based on configured load block size when bus/generator underfrequency is detected. Some user configuration.

Emergency Load Shed Example A C B Output: 12MW Reserve: 13MW Output: 20MW Reserve: 5 MW Output: 15MW Reserve 10MW 1. All Generators connected and loaded as shown. 2. Gen A is lost, 15MW of generation must be compensated for in the system. 3. No load is shed as Gen B and C pick up load from their reserve. Example 1 Output: 0MW Reserve: 0MW Output: 23MW Reserve: 2MW Output: 24MW Reserve: 1MW

Emergency Load Shed Example A C B Output: 20MW Reserve: 5MW Output: 20MW Reserve: 5 MW Output: 20MW Reserve 5MW 1. All Generators connected and loaded as shown. 2. Gen A is lost, 20MW of generation must be compensated for in the system. 3. Total loads shed: 20MW – 5MW (genC reserve) – 5MW(genB reserve) = 10MW. Example 2 Output: 0MW Reserve: 0MW Output: 25MW Reserve: 0 MW Output: 25MW Reserve 0MW

Gradual Load Shed Example A Output: 20MW Reserve Capacity: 5MVA Gradual Shed Threshold: 2MVA Gradual Shed Delay: 5s 1. Generator is connected to a bus and loaded as shown. Gradual Shed Threshold is configured as shown (2MVA) by the operator. 2. Generator Output increases such that Reserve MVA < Threshold MVA 3. One connected load is shed to attempt to unload generator 4. After 5s delay, if Reserve MVA < Threshold MVA then shed next load. If Reserve MVA > Threshold MVA then continue monitoring. Output: 24MW Reserve Capacity: 1MVA Gradual Shed Threshold: 2MVA Gradual Shed Delay: 5s

Underfrequency Shed A C BUS A U/F 1. Two Generators connected as shown. Bus A and C are isolated. Underfrequency Settings: Enabled = TRUE Block Size = 5MW Shed Retry Timer = 5s 2. Bus Underfrequency Alarm A becomes active. 3. 5MW of load attached to genA is shed. 4. After 5s, if U/F is still active, 5MW additional load is shed. If U/F is not active, continue monitoring.

Load Shed Summary Only loads connected to a lost source will be shed. Loads must be determined as available to shed. Loads will be shed in the order of the operator configured priority. Other Generators can pick up load from their reserve only if connected to the lost generator. Total loads to be shed in Fast Acting Load Shedding is continuously calculated and is acted on immediately after receiving signal that a generation source is lost. Load size is determined by actual kW consumption of the load. Operator must configure reserve threshold and time delay for Gradual Load Shed. Operator must configure block size and retry delay for Underfrequency Load Shed

Description of Load Shed Calculations Total Load to Shed = Lost Source kW – Other Connected Gens kW Spinning Reserve kW Spinning Reserve = Smallest value of (Rated Gen kW – Current Gen kW Output) OR (Operator Entered Percentage of Capacity) OR (Operator Entered Fixed Value) Load Size = Measured kW Gradual Shed Reserve Capacity MVA = Generator MVA Capacity – Generator Actual Output MVA Underfrequency Load Block = User Defined MW Reserve Threshold = User Defined MVA

Misc. Topics Data Organization internal to PMS. ICSS interface. MCP/GCP interface. Event Logging. Automatic SWG recovery. Manual Breaker Control. Load Inhibit

PMS Data Organization PMS System uses an object based approach to system control. Breaker Object: Contains information for a breaker. Breaker Status: Open/Closed, Available, Remote etc. Breaker Analog: Power, Voltage, Current etc. Alarms: Ground Fault, Fail to Open, etc. Control: Open Command, Close Command, Inhibit, etc. Modbus Address Motor Object: Contains information for MCC motors. Organized by MCC number, column, bay location (3 dimensional array). MCC [x,y,z] = MCC x, Column y, Bay z Motor Status: HOA_Switch, Inhibited, running, etc. Motor Commands: Start, Stop, etc. Type of motor: HOA, Inhibitable, Controlled through PMS Modbus address.

PMS Data Organization Continued Benefits of Object approach: Leads to simpler code design as each object is examined by single routine. Allows quicker changes to certain aspects such as modifying an input to be normally closed for all motors instead of normally open. Keeps data organized in a manner where support personnel know where to look for important information for each device. Drawbacks: Requires time for initial setup by configuring each object’s attributes i.e. Motor A,B,C has HOA and Motor E,F,G does not. Adding new attributes to an object require that attribute be configured for every object per item above.

Event Logging Timestamps follow data path from each card to each controller to the final database on the HMI server. Routed from Fast, S1, and S2 through Time_Sync controller. Logged in Microsoft Access Database at HMI server. Database available in a readable format from HMI clients. Some points (trip status) SOE stamped for greatest accuracy (<1ms). Other points stamped by PMS controller time. (~100ms accuracy) SOE modules all linked by Sync-Link modules over fiber to coordinate all clocks to be equal. Click to view Data flow: Technical Documents\DETAIL-DESIGN-SPEC\Event Logging Data Flow.vsd

Automatic SWG Recovery Per Operational Philosophy, PMS has the ability to automatically restore essential SWG after loss of power. PMS sequences breakers per recovery sequence to restore SWG. PMS will use Mustang system to control breakers unless Mustang is unavailable, then will use direct control of breakers. OPERATION SWG bus is lost due to main incomer opening. PMS waits to see if essential bus comes online. Then closes XFMR high side. PMS closes secondary when high side is closed PMS checks that essential bus is restored then sequences MCC feeders as specified

Manual breaker control In some cases, operators can choose to open and close breakers manually. PMS sends appropriate modbus commands to breakers to perform desired function. PMS only sends command to a breaker if the breaker is available, the breaker is in remote mode, and the breaker state is opposite of the desired state (a close command is only issued if the breaker is open). Some cases, PMS sends command directly to the breaker. Others through MCP Main SWG controlled directly from PMS Essential SWG controlled normally through Mustang. PMS will send commands to Mustang over modbus TCP to control Breakers. If Mustang is unavailable, PMS will take direct control of breakers.

Load Inhibit Large Loads can be inhibited by the PMS if their starting load size is larger than the spinning reserve of the generation supply. This reserve is the summation of all connected generators M M G M Output: 15MVA Inhibit Spinning Reserve: 4MVA Starting Size: 2200 KVA Inhibit Enabled Starting Size: 8200 KVA Inhibit Enabled Starting Size: 8200 KVA Inhibit Disabled Start OK Start OK No Start

Further Reference www.ab.com – Information on Rockwell Automation Products. www.controlnet.org – Information on ControlNet network. www.odva.org – Information on Ethernet/IP www.modbus.org – Information on Modbus http://hus.hirschmann.com/ - Information on Hirschmann Products www.geindustrial.com/multilin - Information on GE Multilin Products

Pms System Training

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Pms System Training