DCS Upgrade

1.General Information.
Capacity : 2 x 660 MW.
COD Years : 2006.
Scope of Works : DCS, D-EHC, D-AVR, HMI & Network Upgrade.
Estimation Budget : mIDR 79,800
Schedule of Works : November – December 2017.


2.Introduction.
The Steam Power Plant Unit 1 & 2 has COD (Commercial Operating Date) since in 2006 where Plant Operation conduct centralized in Control Room and means by achieved using DCS (Distribution Control and Monitoring System) by TOSMAP – DS (SR06) and will be obsolete in 2018.
The spare-parts of them already manage well but since 2016 the Toshiba as OEM (Original Equipment Manufacturer) no longer to produce of those parts so DCS Upgrade from TOSMAP – DS (SR06) to TOSMAP- DS/LX (SR22) is only solution.
The list DCS obsolete part in 2016-2017 estimation the Units only can be survived until 2018 due to stock near empty.


3.Operation Feasibility.
The typical system configuration of TOSMAP-DS (SR-06) consists of three groups, ACS (Automatic Control System), HMI (Human Machine Interface) and IES (Integrated Engineering Station). They are connected via a dual redundant 100Mbps Ethernet, called C-Net.

The DCS employs fully CRT based operation employing HMI (Human Machine Interface System) and Microprocessor based on digital control system. For Example the Turbine Control based on D-EHC (Digital Electrical Hydraulic Control) and AVR (Automatic Voltage Regulator) for Generator Control are integrated in DCS with seamless communication.

The Boiler monitoring data from local equipment is transferred into PLC on Control Equipment Building. After from its PLC and then continue to transfer into BSQ (Part of DCS Control) through C-Net (Control Network).

The result of its control can be monitored and also can be control check by operator on screen computer through I-Net (Information Network). HMI software is part on I-Net and DCS (CPUW, ETMW card with CPUL Module), (LBIW card with PIFL module), (COMW card with switching HUB), (IOBW card with IOBL Card), (EHC and AVR specific module) and others CPU.

4.Specification
System Architecture
a.Engineering Tools
Middleware: X500
PC – OS : Windows 7
b.HMI
Middleware: TOSMAP SR22
PC – OS : Windows 7
c.Network: UDP/IP – 100M/1Gbps
d.Controller
Firmware : TOSMAP – Linux
Processor : Linux – Intel Celeron

Controller
Processor: Intel Celeron 1.86 GHz.
Operating System: LINUX (Kernel 2.6.33 – rt)
Memory : Main memory 1GB, SSD: 2GB
Packaging of Control Program : Flash ROM (no Battery)
Cycle time: 100 ms – 500 ms
Redundancy: Double Synchronization (Ethernet)
Transmission Rate : Ethernet 1000 Base-T (1Gbps, 5 ch, 100 Base-TX (100 Mbps)
Interface with I/O System: Profibus (1 Gbps, 100 Mbps), TOSMAP I/O (1.25 Mbps, 4 Mbps, Modbus (100 Mbps)
Failure Diagnostics: Watchdog timer, ECC Memory Check, Clock Stop, Voltage Drop, WDT, Temperature, Fans etc.
Dimension : 75 mm (W) x 160 mm (D) x 180 mm (H)
Power supply : 24 V ± 5%
Ambient Temperature : 0 – 50 oC
Ambient Humidity : 5 – 95 %