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ALSPA SERIES 6.0 ALSPA HARDWARE PRESENTATION BY Y BHATNAGAR & NC PAUL
POWER SYSTEMS
Automation is the use of control system to control industrial machinery, and processes, reducing the need for human intervention
Automation plays an increasingly important role in the Various processes like Power Plant, petrochemical, Oil & Gas and in daily experience like Building Automation Different types of automation tools exist: a)DCS - Distributed Control System b)HMI - Human Machine Interface
c)SCADA - Supervisory Control and Data Acquisition d)PLC - Programmable Logic Controller\
DCS:Distributed Control System (DCS) refers to a control system usually of a process or any kind of dynamic system, in which the controller elements are not central in location (like the brain) but are distributed throughout the system with each component sub-system controlled by one or more controllers
OBJECTIVE OF THE PRESENTATION •
INTRODUCTION
•
ALSPA DCS ARCHITECTURE
•
ALSPA MFC 3000 CELL CONTROLLER
•
ALSPA FIELD CONTROLLERS
•
EPL TECHNOLOGY
•
TIME SYNCHRONIZATION
•
EXAMPLES
ALSPA ARCHITECTURE ALSPA CONTROPLANT
CONTROCAD Engineering & Commissioning tool
ALSPA HMI Viewer & RT Data Server
ALSPA Ethernet Enterprise Bus
ALSPA Ethernet Process Bus
ALSPA Ethernet Field Bus
ALSPA MFC3000/1000 Multi-Function Cell Controller
CONTROBLOC Automation Cel CE1500 controller
CE1500 controller
ALSPA Series 6 – Controllers Multi-functions Cell Controllers
MFC3000 Single Rack
MFC3000 Double Rack
MFC1000
Multi-functions Field Controllers and I/Os CE1500
CE2000 Firmware Validation - 29/12/2010 - P 5
CE3000
CE1000
ALSPA Series 6–MFC3000 Controllers with Add. Cards Power On ®
CompactPCI®CompactPCI
CompactPCI®
CF Access Serial Port COM1 (not used) MFC3000 Led (see below)
Ethernet Port (unused)
MFC3000 Led (see below) Reset
Ethernet port for Gate network (HIL access / ALSPA OPC server)
Serial Port COM2
Ethernet Port for Modbus T network Ethernet port for Modbus T network for Trusted(TM) equipment F8000 Medium 1 F8000 Medium 2 Ethernet Port for Redundancy Link
Firmware Validation - 29/12/2010 - P 6
Video Port
Port PS2 Keyboard/Mouse
USB Port (not used)
Ethernet Port 2 S8000 2 / IEC104 Ethernet Port 1 S8000 1
Extractor
ALSPA Product Lines Multi Function Cell Controller: MFC3000 •
The ALSPA MFC3000 Multi-Functions Controller is the master piece of the ALSPA Control System architecture, it performs the following functions: − Automation software application: • • • •
Start-up and Shut-down Sequences Closed loops controls Open loops controls Logic treatments
− Communication with: • Control room or local HMI through the S8000 Unit redundant network • Communication between Automation cells via S8000 Unit redundant network • Field controllers and Distributed I/Os through the E8000 Field redundant network • Other systems through Modbus T/IP • Remote diagnostic functions through the WEB maintenance server communication • Process Simulator through OPC DA
ALSPA Product Lines Multi Function Cell Controller: MFC3000 • Enhanced industrial U fanless – based on Pentium M or Celeron M
• Full dual structure very well adapted for cabinet integration with cabling access in front rack • Floating point computation for optimized data accuracy • Hot swap modules
• Modules in vertical position with natural air cooling • Multiple communication protocols openness (WorldFIP, Fast Ethernet, EPL, Profibus-DP, Modbus T) • Allowing High Availability (Redundancy at all level): − Based on a full hot stand-by redundancy structure − Redundancy of communications (Unit and Field networks) • Integrating Maintenance functions
ALSPA Product Lines Field Controller: CE3000 The ALSPA CE3000 Field Controller is one of the master piece of the ALSPA Control System architecture, it performs the following functions: − Process Data Acquisition and Restitution: • Acquisition of Process data − − − −
Digital inputs Analogue inputs Temperature probes TC Temperature probes RTD/PT100
• Restitution of Process data − Digital outputs − Analogue outputs
− Automation software application: • Fast closed loops for actuators control • Logic treatments
− Communication with: • The redundant Cell Controller through the E8000 redundant Field network
ALSPA Product Lines Field Controller: CE3000 ALSPA CE3000 – Field Controllers S8000 UNIT NETWORK
ALSPA MFC3000 Multi-Function Cell Controller
ALSPA CE3000
ALSPA CE3000
ALSPA CE3000 Field Controllers
ALSPA CE3000
ALSPA CE3000
ALSPA CE3000
ALSPA CE3000
ALSPA CE3000
E8000 Field NETWORK
ALSPA CE3000
Up to 8 CE3000 Field controllers per cell in standard configuration
ALSPA Product Lines Field Controller: CE3000 E8000 network
P o w e r S u p p l y
C P U
E8000 network
16 I/O modules
Analog and Digital I/O
C P U
P o w e r S u p p l y
ALSPA CE3000 Features • Hot Redundancy of U including network communication • Hot redundancy of Power supply • Hot swap of U, Power supply & Modules in operation • Local control with 10, 20, 30, 50, 60, and 100 ms of cycle treatment • Time synchronization • Event time tagging down to 1 ms for all Digital Inputs • Input filtering • Chattering processing • Module isolation at 2500 Volts • Automatic test of I/Os • Fault management of modules • I/Os Wiring facilities
ALSPA CE1000 & CE1500–Controller and Distributed I/Os ALSPA CE SERIES – Distributed Controllers & I/Os S8000 UNIT NETWORK
ALSPA MFC3000 Multi-Function Cell Controller
Up to 16 ALSPA CE SERIES controllers simplex per E8000 field network ALSPA CE SERIES redundant controllers are counted as 2 controllers
E8000 Field NETWORK
Up to 4 CE SERIES cascading blocks per controller CE SERIES Field Distributed I/Os
Up to 100 / 150 I/Os modules per ALSPA CE SERIES nodes
ALSPA CE SERIES – Distributed I/Os Easy to use • Easy to use − Separate: TERMINAL – ELECTRONIC - BUS
− Advantages: • Pre-wiring without system • Hot swapable electronics • Free bus slots for options
− Advantages of rack systems plus advantages of slice systems • Granularity of a slice system • Handling like a rack system • Pre-assembled systems
ALSPA Ethernet Field Bus Hubs
Firmware Validation - 29/12/2010 - P 14
ALSPA EPL Link Selector
Firmware Validation - 29/12/2010 - P 15
Example of MFC3000 and CE3000
Communication
Communication
ALSPA Product Lines Industrial Networks •
Site network − The Site network is based on Fast Ethernet switched network.
•
S8000 Unit network − The Unit network links the three main parts of the plant system (Centralog, Controcad, Controbloc). − The Unit network is based on proven industrial Ethernet network. − The Unit network is based on redundant fail safe solution
•
E8000 Field network − Located at field level, the Field network has highest constraints (high availability, high determinism and performances,…). − The Field network is based on fast and deterministic Real-Time industrial Ethernet network. − The Unit network is based on redundant medium solution with fast switch-over of link
Availability constraints
Performanc e constraints
Determinis m constraints
Site network
na
na
na
Unit network
High
High
High
Field network
Very High
Very High
Very High
ALSPA S8000 Unit Network • The S8000 Unit network is based on proven industrial Ethernet solutions. • High availability is ensured by a fault tolerant ring topology (double ring in case of highest availability is required). • No need for determinism, standard Ethernet is used with IP protocol (T/IP and UDP/IP). • 100Mbits/s or 1Gbits/s, fiber or copper solutions.
ALSPA E8000 Field Network • The E8000 Field network is based on proven industrial Ethernet solutions. • High availability is ensured by a redundant Bus or Star topology. • Need of performance and determinism, use of EPL (Ethernet Power Link) technology based on fast Ethernet using standard IP protocol (T/IP and UDP/IP) and real-time fast Ethernet to ensure determinism exchanges. • 100Mbits/s, fiber or copper solutions.
ALSPA Product Lines Field Network: E8000 E8000 field network based on EPL technology is an open standardized protocol that provides Deterministic Real Time solution over standard Fast Ethernet.
High Speed 100 Mb/s
ALSPA® E8000 Field Network - ETHERNET POWERLINK Fast Real Time Ethernet Field Network
s T/IP and CanOpen protocols Ensures deterministic exchange mechanism Transparent redundancy Standard hardware components
Easy handling allow interoperability
ALSTOM E8000 Field Network:
Benefits
Based on Ethernet Powerlink technology: real time, deterministic, redundant, available and flexible topology.
Guaranteed transfer of time critical data within very short and precise isosynchronous cycles with configurable time
EPL technology is implemented as the high performance field network in ALSPA® control solutions.
Synchronization of all network nodes with high precision in the sub-microseconds range Transmitting less critical data in a reserved asynchronous channel Huge transfer capacity for large I/Os applications.
Communication
Time synchronization
Time synchronization
•
Time synchronization is a problem from computer science and engineering which deals with the idea that internal clocks of several computers may differ
•
Time synchronization can be can be done with variety of protocols like:
NTP,IRIG-B, PTP, etc •
Alspa also uses Time synchronization concept to synchronize its Operator stations, servers, automation cell and field controllers
•
Time synchronization is also used to synchronized time with third party systems
•
Various varity of GPS clock are into the market Like Sertel, Meinberg,Masibus etc
ALSPA Product Lines CE SERIES Field Distributed Controllers Synchronization
GPS Antenna
Meinberg Time server)
CONTROLOG HMI Viewer & RT Data Server
NTP
Time Message
ALSPA S8000 Fast Ethernet Redundant Unit Network IEC870.5 CS104
Redundant Multi-Functions Cell Controller (MFC3000)
5s PULSE
ALSPA E8000 Field Network Time Message & Synchronisation
CE SERIES Field Distributed Controller
ALSPA CE SERIES Digital inputs are time-stamped at 1ms
ALSPA Product Lines Field Controller: CE3000 Synchronization
GPS Antenna
Meinberg Time server)
CONTROLOG HMI Viewer & RT Data Server
NTP
5 sec Pulse
Time Message
ALSPA S8000 Fast Ethernet Redundant Unit Network IEC870.5 CS104
Redundant Multi-Functions Cell Controller (MFC3000)
ALSPA E8000 Field Network Time Message & Synchronisation CE3000 Field Controller
ALSPA CE3000 Digital inputs are time-stamped at source with a precision of 1 ms
Communication
Examples
Example of Network Cubicle
Example of Controller Cubicle
www.alstom.com
POWER SYSTEMS
POWER SYSTEMS
Automation is the use of control system to control industrial machinery, and processes, reducing the need for human intervention
Automation plays an increasingly important role in the Various processes like Power Plant, petrochemical, Oil & Gas and in daily experience like Building Automation Different types of automation tools exist: a)DCS - Distributed Control System b)HMI - Human Machine Interface
c)SCADA - Supervisory Control and Data Acquisition d)PLC - Programmable Logic Controller\
DCS:Distributed Control System (DCS) refers to a control system usually of a process or any kind of dynamic system, in which the controller elements are not central in location (like the brain) but are distributed throughout the system with each component sub-system controlled by one or more controllers
OBJECTIVE OF THE PRESENTATION •
INTRODUCTION
•
ALSPA DCS ARCHITECTURE
•
ALSPA MFC 3000 CELL CONTROLLER
•
ALSPA FIELD CONTROLLERS
•
EPL TECHNOLOGY
•
TIME SYNCHRONIZATION
•
EXAMPLES
ALSPA ARCHITECTURE ALSPA CONTROPLANT
CONTROCAD Engineering & Commissioning tool
ALSPA HMI Viewer & RT Data Server
ALSPA Ethernet Enterprise Bus
ALSPA Ethernet Process Bus
ALSPA Ethernet Field Bus
ALSPA MFC3000/1000 Multi-Function Cell Controller
CONTROBLOC Automation Cel CE1500 controller
CE1500 controller
ALSPA Series 6 – Controllers Multi-functions Cell Controllers
MFC3000 Single Rack
MFC3000 Double Rack
MFC1000
Multi-functions Field Controllers and I/Os CE1500
CE2000 Firmware Validation - 29/12/2010 - P 5
CE3000
CE1000
ALSPA Series 6–MFC3000 Controllers with Add. Cards Power On ®
CompactPCI®CompactPCI
CompactPCI®
CF Access Serial Port COM1 (not used) MFC3000 Led (see below)
Ethernet Port (unused)
MFC3000 Led (see below) Reset
Ethernet port for Gate network (HIL access / ALSPA OPC server)
Serial Port COM2
Ethernet Port for Modbus T network Ethernet port for Modbus T network for Trusted(TM) equipment F8000 Medium 1 F8000 Medium 2 Ethernet Port for Redundancy Link
Firmware Validation - 29/12/2010 - P 6
Video Port
Port PS2 Keyboard/Mouse
USB Port (not used)
Ethernet Port 2 S8000 2 / IEC104 Ethernet Port 1 S8000 1
Extractor
ALSPA Product Lines Multi Function Cell Controller: MFC3000 •
The ALSPA MFC3000 Multi-Functions Controller is the master piece of the ALSPA Control System architecture, it performs the following functions: − Automation software application: • • • •
Start-up and Shut-down Sequences Closed loops controls Open loops controls Logic treatments
− Communication with: • Control room or local HMI through the S8000 Unit redundant network • Communication between Automation cells via S8000 Unit redundant network • Field controllers and Distributed I/Os through the E8000 Field redundant network • Other systems through Modbus T/IP • Remote diagnostic functions through the WEB maintenance server communication • Process Simulator through OPC DA
ALSPA Product Lines Multi Function Cell Controller: MFC3000 • Enhanced industrial U fanless – based on Pentium M or Celeron M
• Full dual structure very well adapted for cabinet integration with cabling access in front rack • Floating point computation for optimized data accuracy • Hot swap modules
• Modules in vertical position with natural air cooling • Multiple communication protocols openness (WorldFIP, Fast Ethernet, EPL, Profibus-DP, Modbus T) • Allowing High Availability (Redundancy at all level): − Based on a full hot stand-by redundancy structure − Redundancy of communications (Unit and Field networks) • Integrating Maintenance functions
ALSPA Product Lines Field Controller: CE3000 The ALSPA CE3000 Field Controller is one of the master piece of the ALSPA Control System architecture, it performs the following functions: − Process Data Acquisition and Restitution: • Acquisition of Process data − − − −
Digital inputs Analogue inputs Temperature probes TC Temperature probes RTD/PT100
• Restitution of Process data − Digital outputs − Analogue outputs
− Automation software application: • Fast closed loops for actuators control • Logic treatments
− Communication with: • The redundant Cell Controller through the E8000 redundant Field network
ALSPA Product Lines Field Controller: CE3000 ALSPA CE3000 – Field Controllers S8000 UNIT NETWORK
ALSPA MFC3000 Multi-Function Cell Controller
ALSPA CE3000
ALSPA CE3000
ALSPA CE3000 Field Controllers
ALSPA CE3000
ALSPA CE3000
ALSPA CE3000
ALSPA CE3000
ALSPA CE3000
E8000 Field NETWORK
ALSPA CE3000
Up to 8 CE3000 Field controllers per cell in standard configuration
ALSPA Product Lines Field Controller: CE3000 E8000 network
P o w e r S u p p l y
C P U
E8000 network
16 I/O modules
Analog and Digital I/O
C P U
P o w e r S u p p l y
ALSPA CE3000 Features • Hot Redundancy of U including network communication • Hot redundancy of Power supply • Hot swap of U, Power supply & Modules in operation • Local control with 10, 20, 30, 50, 60, and 100 ms of cycle treatment • Time synchronization • Event time tagging down to 1 ms for all Digital Inputs • Input filtering • Chattering processing • Module isolation at 2500 Volts • Automatic test of I/Os • Fault management of modules • I/Os Wiring facilities
ALSPA CE1000 & CE1500–Controller and Distributed I/Os ALSPA CE SERIES – Distributed Controllers & I/Os S8000 UNIT NETWORK
ALSPA MFC3000 Multi-Function Cell Controller
Up to 16 ALSPA CE SERIES controllers simplex per E8000 field network ALSPA CE SERIES redundant controllers are counted as 2 controllers
E8000 Field NETWORK
Up to 4 CE SERIES cascading blocks per controller CE SERIES Field Distributed I/Os
Up to 100 / 150 I/Os modules per ALSPA CE SERIES nodes
ALSPA CE SERIES – Distributed I/Os Easy to use • Easy to use − Separate: TERMINAL – ELECTRONIC - BUS
− Advantages: • Pre-wiring without system • Hot swapable electronics • Free bus slots for options
− Advantages of rack systems plus advantages of slice systems • Granularity of a slice system • Handling like a rack system • Pre-assembled systems
ALSPA Ethernet Field Bus Hubs
Firmware Validation - 29/12/2010 - P 14
ALSPA EPL Link Selector
Firmware Validation - 29/12/2010 - P 15
Example of MFC3000 and CE3000
Communication
Communication
ALSPA Product Lines Industrial Networks •
Site network − The Site network is based on Fast Ethernet switched network.
•
S8000 Unit network − The Unit network links the three main parts of the plant system (Centralog, Controcad, Controbloc). − The Unit network is based on proven industrial Ethernet network. − The Unit network is based on redundant fail safe solution
•
E8000 Field network − Located at field level, the Field network has highest constraints (high availability, high determinism and performances,…). − The Field network is based on fast and deterministic Real-Time industrial Ethernet network. − The Unit network is based on redundant medium solution with fast switch-over of link
Availability constraints
Performanc e constraints
Determinis m constraints
Site network
na
na
na
Unit network
High
High
High
Field network
Very High
Very High
Very High
ALSPA S8000 Unit Network • The S8000 Unit network is based on proven industrial Ethernet solutions. • High availability is ensured by a fault tolerant ring topology (double ring in case of highest availability is required). • No need for determinism, standard Ethernet is used with IP protocol (T/IP and UDP/IP). • 100Mbits/s or 1Gbits/s, fiber or copper solutions.
ALSPA E8000 Field Network • The E8000 Field network is based on proven industrial Ethernet solutions. • High availability is ensured by a redundant Bus or Star topology. • Need of performance and determinism, use of EPL (Ethernet Power Link) technology based on fast Ethernet using standard IP protocol (T/IP and UDP/IP) and real-time fast Ethernet to ensure determinism exchanges. • 100Mbits/s, fiber or copper solutions.
ALSPA Product Lines Field Network: E8000 E8000 field network based on EPL technology is an open standardized protocol that provides Deterministic Real Time solution over standard Fast Ethernet.
High Speed 100 Mb/s
ALSPA® E8000 Field Network - ETHERNET POWERLINK Fast Real Time Ethernet Field Network
s T/IP and CanOpen protocols Ensures deterministic exchange mechanism Transparent redundancy Standard hardware components
Easy handling allow interoperability
ALSTOM E8000 Field Network:
Benefits
Based on Ethernet Powerlink technology: real time, deterministic, redundant, available and flexible topology.
Guaranteed transfer of time critical data within very short and precise isosynchronous cycles with configurable time
EPL technology is implemented as the high performance field network in ALSPA® control solutions.
Synchronization of all network nodes with high precision in the sub-microseconds range Transmitting less critical data in a reserved asynchronous channel Huge transfer capacity for large I/Os applications.
Communication
Time synchronization
Time synchronization
•
Time synchronization is a problem from computer science and engineering which deals with the idea that internal clocks of several computers may differ
•
Time synchronization can be can be done with variety of protocols like:
NTP,IRIG-B, PTP, etc •
Alspa also uses Time synchronization concept to synchronize its Operator stations, servers, automation cell and field controllers
•
Time synchronization is also used to synchronized time with third party systems
•
Various varity of GPS clock are into the market Like Sertel, Meinberg,Masibus etc
ALSPA Product Lines CE SERIES Field Distributed Controllers Synchronization
GPS Antenna
Meinberg Time server)
CONTROLOG HMI Viewer & RT Data Server
NTP
Time Message
ALSPA S8000 Fast Ethernet Redundant Unit Network IEC870.5 CS104
Redundant Multi-Functions Cell Controller (MFC3000)
5s PULSE
ALSPA E8000 Field Network Time Message & Synchronisation
CE SERIES Field Distributed Controller
ALSPA CE SERIES Digital inputs are time-stamped at 1ms
ALSPA Product Lines Field Controller: CE3000 Synchronization
GPS Antenna
Meinberg Time server)
CONTROLOG HMI Viewer & RT Data Server
NTP
5 sec Pulse
Time Message
ALSPA S8000 Fast Ethernet Redundant Unit Network IEC870.5 CS104
Redundant Multi-Functions Cell Controller (MFC3000)
ALSPA E8000 Field Network Time Message & Synchronisation CE3000 Field Controller
ALSPA CE3000 Digital inputs are time-stamped at source with a precision of 1 ms
Communication
Examples
Example of Network Cubicle
Example of Controller Cubicle
www.alstom.com
POWER SYSTEMS
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