Software manual

Software and hardware locks and protection by water level

Software manual
The structure of the controller‘s program 

ANNOTATION

This document describes the purpose, conditions of use and characteristics of PLC applications software. Applications software of industrial computer (PC) is described in the User’s Guide.

CONTENT
1. PURPOSE AND APPLICATION SOFTWARE

1.1. Purpose of PLC applications software
1.2. Conditions of use PLC applications software
2. DESCRIPTION OF THE PROGRAMME
2.1. The structure of the PLC applications software
2.2. Data structures of PLC applications software
2.3. User’s function blocks used in Unity applications software
3. REFER TO THE PROGRAM
4. INPUT AND OUTPUT DATA
5. MESSAGES
1. PURPOSE AND APPLICATION SOFTWARE
Block TCP and protection of the water level in the steam generator units №1,2 Power is designed to protect the piping system of steam generators at lower water levels and protect the system from casting feedwater flow part of the turbine at an elevated level in the steam generator.
Process protection provided by a complex technological equipment:

Valves on the main feedwater line (AM-9);
Valves on the main feedwater lines (VP-10);
Valves on the purge line (U5-01);
Valves on the purge line (U5-02);
Valves on the bypass water supply (VP11);
Teams enable emergency electric pump Booster (APEN-1);
Teams enable emergency electric pump Booster (APEN-2);
The trip command of the turbogenerator (TG3);
The trip command of the turbogenerator (TG4);
Issuance of technological alarm on the lowering of the level in 4 of the 6 GHG
Issuance of technological alarm protection operation + 300mm
Team disconnect power to the regulator vent line + 75mm
Team disconnect power to the regulator vent line 500 tons
Extradition process signaling + 125mm
Extradition process signaling + 75mm
Issuance of technological alarm ± 50mm
Issuance of technological alarm on the -120mm
Issuance of technological alarm on the 500t / h

Operation of the system is provided by the application software.
Application software includes application software of industrial computer and PLC applications software.

1.1. Purpose of PLC applications software
PLC applications software as part of the TCP performs the following functions:
– Redundancy controllers;
– Receiving and processing signals from the input-output three identical baskets O;
– Receives and filters the input digital signals of a possible “bounce” contacts.
– Receive and process analog signals:
• provides the control signal output of range (unreliability of the signal);
• produces a scaling of the analog signal;
• carries hysteresis thresholds;
• analyzes the state of the three signals from the baskets and reliable sample values;
• filters the signal for the rate of increase or decrease of the value of the signal.
– Issuance of digital signals for equipment (protection operation);
– Control parameters deviations from targets and achieve laden with values;
– Issuance of executive actions on technological alarm lights in the control room;
– Implementing algorithms of protections and interlocks;
– Data exchange with adjacent systems via Modbus / TCP / IP;
– Check the controller module for errors, and the formation of messages for workstation equipment status controller and panel control room;
– Monitoring of emergency equipment;
– PPO PLC enables the reception of the industrial PC and panel control room keys disable certain protection and locking system.

1.2. Conditions of use PLC applications software

Complex software and hardware including the following hardware and software components purchased:
1) Two programmable logic controller (PLC) QUANTUM processor-based P266 CPU, working in hot standby mode. Runtime Environment Unity Pro 4.1 XL.
2) An industrial computer, consisting of:
– Personal computers (embedded industrial computer);
– Operating system Windows XP Pro SP3;
– Package visualization SITECT 7
PLC reacted with external subsystems over Ethernet (by PLC) and input-output channels.
Interaction PLC and industrial PC is carried out via Ethernet.
Hardware and software components include application software developed under this project:
Appendix Unity Pro, mounted on the PLC.
Appendix Citect, installed on a PC.

2. DESCRIPTION OF THE PROGRAMME
2.1. The structure of the PLC applications software
PLC applications software is implemented as an application, written in the environment of Unity v.4.1. Application Name – upg.stu.
Appendix upg.stu provides the functionality of the system, implemented in the PLC for all modes of operation.
The application includes:
• configuration of hardware and software;
• set of functional modules, each of which implements sections, written in LD (ladder diagram);
• A set of function blocks developed within the project;
• a database;
• animation table.
The application includes the following functional modules:
Name section Functionality
Init section performed at the first cycle after start-up and provides the assignment of initial values ​​of all parameters.
AI_to_AM Section processing analog input signals. Block calls the appropriate signal for assigning a value to an internal variable and validation channel.
DI_to_DM handling section of discrete input variables. Calling the function block signal corresponding to assign a value to an internal variable and validation channel.
Comparing section comparing the values ​​obtained from three different baskets distributed IO. The signals are compared by the logic of 2 of 3. If the two signals are identical, while the third is different, the latter shall be deemed invalid.
Name section Functionality
Alarms Section processing of digital and analog signals to determine the limit value. Generation of alarms and commands to execute blocking and protection.
INTERLOCK Section forming algorithm blocking and protection. In this section there is a record in variables associated with actuators.
Section SIM mode control simulation and testing of the controller.
DIAGNOSTIC section forming the diagnostic information of the controller.

Inside the section, the following routines:
Name section Functionality
CompANY function block for comparing three different analog values, issue the resulting output values ​​as well as diagnostic information for each channel.
CompDI function block for comparing the three discrete signals coming from three different baskets, issuing output the resulting value, and diagnostic information for each channel.
BlockF functional unit for fixing unacceptably rapid fall or gain of an analog value. In the case of open or short circuit the SE displays the signal from the processing that will not allow to stop the process.
GetDI functional unit for receiving and processing digital signals. Filters out сontacts bounce.

Name section Functionality
HRLA4 functional unit designed to produce four threshold violations from one analog signal (HH, H, L, LL). The FB parameters are taken into account hysteresis and dead zone for fixing violations.
GetAI functional unit for receiving and processing analog signals. Performs scaling values, and also serves as a partial smoothing.
SIMPMEHA Functional unit designed for the issuance of a sinusoidal interference. This interference “mixed into” a simulated sound to add realism when dealing with such regimes as “testing.”
SIMPULSE functional unit, intended for delivery in the pulse of predetermined duration.
SIMPV functional unit designed to simulate analog value when dealing with such regimes as “testing.”
2.2. The structure of the PLC applications software

Total energy in each block is the six steam generators and software elements of PPO carried out for each of them identical.
The project controller software uses the following data types:
 The status word is an analogue channel – type of word;
 Status word discrete channel – type of word;
 word defines the value of the analog channel – type real (word or two word);
 The status word controller QUANTUM – type of word (reserved just two words);
 Status Word violations – the type of word;
 Status word lock – type of word;
 Status word Unblocking Key – type of word;

Industrial computer control allows exposure only for unblocking key, by changing the state of bits via control word. PLC informs about its status via status word. Description of individual fields (bits) of data words in the guidelines of the programmer.

Variables in the PLC are encoded as follows:
 AI – analogue input in PLC;
 AIM – the internal analog input PLC / PC;
 DI – digital input to the PLC;
 DM – internal digital input PLC / PC.

2.3. User’s function blocks used in Unity applications software
2.3.1 Comparator function block analog channels CompAI

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Picture 1. Comparator function block analog channels CompAI

This function block is used for comparison of three different analog values. If one of the analog parameters beyond the average of the other two, then it is not taken into account and the property of the written channel error. If all three channels are OK (acceptable tolerances are in error), the result will be the greater of the current value.

2.3.2 Comparator function block analog channels CompDI

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Picture 2. Comparator function block analog channels CompDI

This function block is used to compare the three pairs of digital signals. If the two values of the pair of signals are the same, it would mean an open or short circuit. In this case, the pair is ignored and removed from circulation. The system displays a message indicating the nature of the cause disturbances. If the total value of three different pairs are different, then the algorithm outputs a block of treatment are those which do not correspond to the previous two.
2.3.3 Function block calculating the decay rate of an analog value BlockF

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Picture 3. Function block calculating the decay rate of an analog value BlockF

This function block is used to calculate the rate of rise and fall in the value of the analog channels. If a wire break occurs on the analog sensor or a sharp drop in physical values, the parameter to be read with this sensor will begin to plummet. This FB is used to fix the event of short-circuit or open-write-word channel status indication errors. That is, when an open or short circuit the channel will be output from circulation.

2.3.4 Function block scaling of analog channel GetAI

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Picture 4. Function block scaling of analog channel GetAI

This function block is used to transfer program units controller (INT) in the value of the actual process units (REAL). In case of setting the boundaries of permissible error (OFFSET) error on the channel option is issued and stops at the maximum or minimum value. If the option is allocated more normalized error, you get an error on the channel with a breakdown of the nature of the violation.

2.3.5 The function block processing discrete channel GetDI

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Picture 5. The function block processing discrete channel GetDI

This function block is used to filter the “bounce” on the digital channels. In the case of loss of communication with the channel to the input of the FB writes a predetermined value, so that the output of the function block in the resulting output will be written down value set by default.

2.3.6 Function block development of threshold violations HLLA4

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Picture 6. Function block development of threshold violations HLLA4

This function block is used for the realization of four threshold violations, which can be used for the issuance of systemic disorders, and to implement them in the implementation of algorithms interlocks and protections. To breach did not vanish immediately upon the return of the area the set value, provided hysteresis function, affecting the nature of outputting signals of abuse.

2.3.7 Function block generating a sinusoidal interference SIMPMEHA

8Picture 7. Function block generating a sinusoidal interference SIMPMEHA

This function block is used to implement mode controller associated with debugging and simulated operation. The signal on the chart looks like a sine curve with a tolerance range limit (input variables). This signal is designed for the “mixing” to the value of the analog signal and to make it dynamic properties and visual realism.

2.3.8 Function block generating pulses of predetermined length SIMPULSE

9Picture 8. Function block generating pulses of predetermined length SIMPULSE

This function block is used to implement mode controller associated with debugging and simulated operation. This signal appears in the diagram as a square wave, with different ranges of peaks and valleys. Temporary peaks meandering values specified time limits (input variables).

2.3.9 Function block generation analog variable SIMPV

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Picture 9. Function block generation analog variable SIMPV

This function block is used for generating analog signals for the simulation mode of the devices and debug controller.

3. REFER TO THE PROGRAM
The program is at work at the site is configured to start automatically when you turn on the controller. Program status displayed on the controller. Configuring the program can be carried out with a portable computer in the supply system.

4. INPUT AND OUTPUT DATA
The input to the system is the information from the object management software and hardware devices through communication with the object (distributed periphery), and the commands entered by the operator from the PC.
The output of the system is the information transmitted to the control object of the software and hardware through a device with the object. The information is displayed on the PC in the form of screens and comes in the form of a signaling panel unit control panels.

5. MESSAGES
Messages sent by PLC-PC interface are described in the “Software manual. Part 2. Interface PC-PLC. “Messages issued by the operator are described in the Operator’s manual.