How can I Develop a time stamping application in PlantStruxure? System Technical Guide Time Stamping solutions Develop your project
Disclaimer This document is not comprehensive for any systems using the given architecture and does not absolve users of their duty to uphold the safety requirements for the equipment used in their systems or compliance with both national or international safety laws and regulations. It is assumed that readers already know how to use the products described in this document. This document does not replace any specific product documentation. 3
The STG Collection System Technical Guides (STG) are designed to help project engineers and Alliance System Integrators during the development of a project. The STGs support users during the architecture selection and the project execution (design, configuration, implementation and operation) phases with an introduction to the system operating modes. Each STG is a starter kit that provides users with: Technical documentation Application examples Object libraries Each STG addresses one or several customer challenges within the proposed solution using the offer from Schneider Electric. All explanations and applications have been developed by both Schneider Electric experts and system integrators in our solution labs. The contributions from the system integrators help the kit s content meet the expectations of our users. All STGs are illustrated with industry-specific applications to give more concrete examples of the methodology. STGs are not intended to be used as substitutes for the technical documentation related to the individual components, but rather to complement these materials and training. Development Environment Each STG has been developed in one of our solution platform labs using a typical PlantStruxure architecture. PlantStruxure, the Process Automation System from Schneider Electric, is a collaborative system that allows industrial and infrastructure companies to meet their automation needs while also addressing growing energy management requirements. Within a single environment, measured energy and process data can be analyzed to help build an optimized plant. 4
Table of Contents Quick Start Guide...7 1. Introduction...9 1.1. Purpose... 9 1.2. Introduction to time stamping... 9 1.3. Challenges... 12 1.4. Prerequisites... 12 1.5. Methodology... 12 1.6. Limitation... 13 2. Selection...15 2.1. Selection criteria... 15 2.2. Selection steps... 15 2.3. Solution list... 17 3. Design...21 3.1. System hardware design... 21 3.2. System software design... 23 3.3. DFB design... 24 3.4. SCADA design... 37 4. Configuration...41 4.1. Time stamped by module... 41 4.2. Time stamped by program... 44 5. Implementation...47 5.1. PAC... 47 5.2. SCADA... 50 5
6. Operation...53 6.1 Time stamping diagnostics... 53 6.2 Time stamping alarms... 54 7. Hydro power plant example...55 7.1. Introduction to the hydro power plant process... 55 7.2. Application background... 56 7.3. System architecture... 57 7.4. PAC application... 58 7.5. SCADA application... 60 7.7. Device list... 63 Appendix...65 Abbreviations... 65 6
Quick Start Guide Quick Start Guide The goal of this System Technical Guide (STG) is to provide recommendations, guidelines, and examples to help develop a time stamping solution effectively and reliably for a typical PlantStruxure architecture. To get the most out of this STG, please consider the following suggestions:: - If this is the first time you are using the time stamping application, we recommend that you read the entire STG before proceeding. - If you are already familiar with time stamping technology and want to define a solution for your application, you can start at Chapter 2. - If your solution architecture is defined and you want to setup your application, you can start at Chapter 3. - If you already have knowledge about implementing time stamping applications with Schneider products and you want to see some real examples, please go to Chapter 7 of this STG. 7
1-Introduction 8
1-Introduction 1. Introduction 1.1. Purpose With continuous developments in industry and technology, more and more automation systems are being implemented in different fields. For better control and maintenance of complex systems, end users of these automation systems require processing data with time stamps. This guide proposes a method to implement a time stamping solution using a Programmable Automation Controller (PAC) and a SCADA system. Moreover, this STG suggests the best practices to follow to take advantage of system openness while reducing the risks of misuse and misunderstandings. The recommendations and guidelines provided in the following chapters are generic and targeted at time stamping applications such as tracking a sequence of events (SOE) or time stamping alarms. However, we use the specific example of a sequence of events (SOE) function in a hydro power plant to illustrate a time stamping application in a process control system. 1.2. Introduction to time stamping 1.2.1 What is time stamping? A time stamp in an automation system is the time information of when a signal event occurred. It is recorded by the control units in a consistent format. The function of recording the time stamps is called time stamping. Time stamping is an important function for tracking processes in some automation systems, such as hydro power plant control and oil pipeline control. This function provides operators with a method to better identify process sequences in a large and complex system, to fine tune protection and control schemes, and improve overall system reliability. One of the most important applications of time stamping is to help track down the root causes after a system error is detected. 1.2.2 What is the process flow of the time stamping function? The time stamping function in a process automation system can be implemented in three steps: time sourcing, stamping time on the event data, and monitoring & inquiry. The following flow chart shows the time stamping process: 9
1-Introduction Figure 1 Time stamping process Time synchronization A process that uses a clock reference to synchronize the time used for stamping. A standalone source with a regulated time provides the clock reference used to synchronize the time clock for stamping. There are three different types of clock references that can be used in Schneider Electric Programmable Automation Controller (PAC) systems: PC time Network Time Protocol (NTP) server time DCF77 signal time The time clock used for stamping is the internal clock which is typically located in PAC modules or time servers. They can be synchronized with an appropriate clock reference depending on application needs. Generally, there are three types of time clocks that can be used in a PAC system: Real Time Clock (RTC) which is in the CPU Network Time Protocol (NTP) server clock ERT clock The next table shows the way the time clock is synchronized with the clock reference. 10
1-Introduction Table 1 Synchronization between the clock reference and time clock Time stamps on the event data performs the time stamping function. The PAC system records the time data with the time clock when the event occurs and associates the time information with the event signal data. Monitoring & data inquiry manages the time stamped data. The time stamped data is displayed and recorded on the SCADA system. The time stamped data can be used in different applications such as sequence of events (SOE) and alarm signals. The data history helps the user to analyze the event sequence. 1.2.3 Benefits of a time stamping application Time stamping in automation systems helps with process control and maintenance by adding a timestamp to every event. In a complex automation system, many events can cause the system to error and stop the system. Because of the mass of information the system provides when stopping, finding useful information can be tricky. Time stamping provides a way of ordering the information with time stamps making it simpler to track errors.. For example, suppose four discrete events -A, B, C, and D as shown in Figure 2 impact on each other. A detected error in one of the events can trigger a chain reaction preventing the other three from running successfully and resulting in an emergency stop. If there are no time stamps on the event records, it becomes very difficult to say which of the events caused the stop. With the time stamping function, the events are sequentially recorded with time information, enabling quicker and easier maintenance as the user can see which of the events started the chain reaction that caused the system to stop. This is the benefit of the time stamping function in a complex system. 11
1-Introduction 1.3. Challenges Figure 2 Event sequence analysis with and without time stamping function This STG uses a hydro power plant (HPP) automation process system as an example to illustrate the application of time stamping. The HPP system is detailed in Chapter 7. For customers in industries that require the time stamping application mentioned above, the challenges are: Time synchronization Time resolution Time accuracy Implementation in a large scale system 1.4. Prerequisites Schneider Electric recommends that the user have knowledge of the following systems: Schneider Electric PACs Quantum, Premium and M340. Schneider Electric software - UnityPro, Vijeo Citect and OPC Factory Server 1.5. Methodology This STG explains the project methodology and includes the following phases: Selection, Design, Configuration, Implementation and Operation. A step-by-step 12
1-Introduction methodology is provided to create a time stamping application. Here is an overview of this method: Selection: In this phase, you will decide the selection criteria and steps that will guide you to select the most appropriate solution for your application requirements. Design: This phase comprises four main parts: System hardware design: how to develop the time stamping system hardware. System software design: how to develop time stamping with Schneider Electric software. Derived Function Block (DFB) design: provide a package of the DFBs for the time stamping application. SCADA design: how to develop Vijeo Citect time stamping genies. Configuration: This phase explains how to set up the time stamping application: How to set up time clock synchronization with references How to set up a time stamping solution by module How to set up a time stamping solution by program Implementation: This phase explains the programming requirements: The PAC part explains how to set up the time stamping sections. The SCADA part explains how to set up the Vijeo Citect time stamping genies and alarms. Operation: This phase presents the capabilities of the final SCADA application: How to use Vijeo Citect time stamping genies How to use the time stamping alarms 1.6. Limitation The accuracy of timestamps relies on the accuracy of the clock reference. It is also impacted by the transmission mode. For example, when the CPU RTC gets the time from the NTP server, the time is delayed by the transmission through the network. A method must be developed to calculate the delay and adjust the clock reference as needed. This is not in the scope of this STG. For the Purposes of this guide, we assume that the time used for time stamping does not suffer any delay. 13
2-Selection 14
2-Selection 2. Selection 2.1. Selection criteria This chapter describes the selection of the components needed to build a time stamping application and provides a solution list. Each automation control project has specific requirements and constraints, such as the size of the plant, control complexity, and project budget. The time stamping resolution is a very important requirement of the project. The requirements and constraints defined in the project specification are used as guidelines to select the time stamping solution. There are three criteria for the time stamping application selection: Time resolution System scale (complexity) Cost 2.2. Selection steps According to the selection criteria, the time stamping solution is developed in four steps: Selecting a time stamping method and mode Selecting a PAC platform Selecting an I/O architecture Selecting a CPU task mode 2.2.1. Selecting a time stamping method and mode Two different time stamping methods can be used, time stamped by module or time stamped by program. 15
2-Selection Figure 3 Time stamping methods and modes Time stamped by module is a time stamping method using a Quantum expert time stamped module 140 ERT 854 10. With this method, the ERT mode is used. In ERT mode, the events are stamped by the ERT clock in the ERT module and sent to the PAC during system scan. The PAC only needs to reformat the time stamps for the SCADA system. Time stamped by program is a time stamping method performed by the application program. With this method, two modes of time synchronization can be used: RTC mode, the time stamps are made with the CPU Real Time Clock. The RTC is updated by PC time or NTP server time. The input signal is obtained by a discrete or expert input module. The PAC system combines the RTC and input data to produce the timestamped data in a format that can be accepted by the SCADA system. NTP mode, the time stamps are made with the NTP server clock. The input signal is obtained by a discrete or expert input module. The PAC system combines the NTP server clock and input data to produce time stamped data in a format that can be accepted by the SCADA system. 2.2.2. Select PAC platform There are three PAC platforms that can be selected: Quantum, Premium and M340; however, only the Quantum CPU supports the ERT module. Thus, the time stamped by module method can only be implemented on a Quantum system. 16
2-Selection 2.2.3. Select I/O architecture Three I/O architectures can be selected: local I/O, remote I/O and distributed I/O. Systems with local I/O can achieve high resolution time stamps. For remote I/O and distributed I/O, the time stamp resolution is limited by the PAC MAST task scan cycle. I/O architecture depends on the PAC platform. The following table shows the I/O architectures for different PAC platforms. Table 2 Supported I/O architecture on each PAC platform Note: The local I/O architecture is not fully supported by Quantum hot standby. 2.2.4. Select CPU task mode 2.3. Solution list Three task modes can be selected: MAST, FAST and EVENT task modes. Only the local I/O architecture supports the FAST and EVENT tasks. If users select the remote I/O or distributed I/O, then the FAST task and EVENT task modes are not available, and the time stamp resolution is lower. Note: 1. The EVENT task is only supported by the Quantum platform. The expert module reference is 140 HLI 340 00. 2. Task mode is not considered in the time stamped by module method. In this case, the time stamping is dealt with in module and not in program. The task mode is only available in the program, not the module. According to the selection procedure, a number of solutions using Schneider Electric s PlantStruxure products are provided to help the user make a decision based on the application requirements. The following list presents the most representative solutions for time stamping applications. 17
2-Selection Table 3 Solution list for time stamping function Table 3 notes: 1. The time stamped resolution can be evaluated with the task scan time. Take solution #3 for example, if the PAC FAST task scan time is set to 1 ms, the time stamping resolution is 1 ms. 2. The time stamped resolution can be evaluated with the task scan time plus the translation delay of NTP server clock. Take solution # 8 for example, if the PAC FAST task scan time is set to 1 ms and the NTP clock delay time is 10 ms, the time stamping resolution is 11 ms. 3. Scale means the complexity of the system. Small system - Less than 250 I/O points Medium system - More than 250 but less than 1000 I/O points Large system More than 1000 I/O points Based on the Table 3 solution list, two typical solutions are selected for further exploration: Solution #2. The system is built on the Quantum platform using the method of time stamped by module. It can meet the requirements of a large system with high time stamp resolution. Solution #8. The system is built on the M340 platform using the method of time stamped by program. It is economical and suitable for medium and small systems that do not have critical requirements for the time stamp resolution. 18
2-Selection These two solutions are the ones used in the Design, Configuration, Implementation, and Operation chapters. 19
3-Design 20
3-Design 3. Design This chapter presents system hardware, system software, DFBs, and SCADA design that can help the user build a time stamping application. 3.1. System hardware design There are two kinds of time stamping hardware designs, depending on whether the user chooses the time stamped by module method or the time stamped by program method. Time stamped by module This solution is designed for a Quantum system to implement the function of time stamping by ERT module. The clock reference is in DCF77 format, provided by a GPS receiver. The signal data is automatically time stamped by the ERT.. A 1 ms time stamp resolution can be obtained in this application. As shown in Figure 5, the system includes the following parts: Modicon Quantum Hot Standby system (140 CPU 671 60) with remote I/O module Time stamping module (140 ERT 854 10) NTP client module (140 NOE 771 11) GPS (Global Positioning System) receiver, including NTP server unit and DCF77 unit Note: NTP server unit provides a clock reference to synchronize the PC time with the PAC system time. 21
3-Design Figure 4 System architecture for time stamped by module Time stamped by program There are two ways to implement the method of time stamped by program. Here we use the example of NTP mode. The solution is designed based on the M340 system. The clock reference is provided by the NTP server, and the signal data is time stamped by a CPU program. As showed in Fig 6, the system includes the following parts: M340 system (BMX P34 2020) with I/O module, NTP client module (BMX NOE 0100) GPS (Global Positioning System) receiver, including NTP server unit 22
3-Design The GPS receiver with NTP server provides the time signal to each client by Ethernet. The CPU obtains the time information through the NTP client module in M340 system. Time stamps with 5-10 ms resolution can be achieved by NTP mode. GPS Receiver Human Machine Interface(HMI) NTP Server Ethernet TCP/IP NTP synchronizing Ethernet Switch M340 PLC BMX XBP 0600 CPS CPU NOE DDI_1 CPS2000 DC24V P34 2020 Modbus, Ethernet NOE 0100.2 DDI 1602 Signal source Figure 5 System architecture for time stamped by program (NTP mode) 3.2. System software design The software used in this STG are based on SoCollaborative, which is a part of PlantStruxure. Three SoCollaborative software components are needed in the design of the time stamping function: Vijeo Citect OFC Factory Server Unity Pro In the Process Operator s Station: Vijeo Citect Run Time is used to display the time stamping value. OPC Factory Server is used to connect to the PAC system. 23
3-Design In the Process Engineering Station: Vijeo Citect configuration is used to design the time stamping monitoring system. OPC Factory Server configuration is used to set up the communication between the Vijeo Citect (SCADA) and the PAC. Unity Pro is used to design the PAC system. Figure 6 shows the data exchange method among the three SoCollaborative software components. Figure 6 Data exchange among the SoCollaborative software components 3.3. DFB design To help the users set up the time stamping program easily with Unity PACs (Quantum, Premium, M340), five DFBs are designed for the time stamping solution. TS_RTC TS_NTP 24
3-Design TS_ERT TS_DataBase TS_DataBase_To_VJC These DFBs can be applied to the different solutions mentioned in Chapter 2. The definition of the DFB function and data type are explained further on. The overall function list of the DFB package is shown in Table.4. Table 4 DFB list for time stamping function 25
3-Design Figure 7 shows the program architecture for time stamping Figure 7 Program architecture of the time stamping function Time stamping by program handles all of the data processing compared to the time stamping by module method, which only handles the data acquisition and reformatting from the ERT module. 26
3-Design DFB1: TS_RTC Function: The TS_RTC DFB is designed for time stamping with the RTC mode. It adds the time stamp to the event data with RTC time, and sends out the time stamps. With this function block, the users choose the detection mode for time stamps. This DFB also handles a buffer of up to 100 records of time stamped data. Data type: DFB type: TS_RTC DFB input/output types: 27
3-Design The table below gives parameter definitions: TS_RTC_DFB Input No Parameter Type Comment 1 Input TS_DDT_Input TS_DDT_Input.module (BYTE): inputs module number TS_DDT_Input.in (ARRAY[1..16] OF BOOL): 16 discrete inputs 2 Mode INT mode=1: TS with input Rising edge detection mode=2: TS with input Falling edge detection mode=3: TS with both Rising and Falling edge detection 3 Ack BOOL Acknowledgement of the new TS A Rising edge of Ack can trigger an acknowledgment of one TS. If Ack is set to 1, a new TS is always acknowledge. 4 Reset BOOL error reset, buffer reset Output No Parameter Type Comment 1 RTC_time Display_NTPC Display_NTPC.DT_Value: real RTC time and data Display_NTPC.Millisecond: real RTC ms 2 nd_ts BOOL nd_ts=1: New TS in the buffer nd_ts=0: The buffer is empty 3 Ts TS Time stamping struct: TS.in (WORD): D0~D5: the channel number of the discrete input D6, D7: the mode of the input. (01: Rising edge, 10: Falling edge) D8~12: the module number of the input signal TS.ms (WORD): ms part of the time stamp TS.hour_min (WORD): hour and minute part of the time stamp (BCD type) TS.month_day (WORD): month and day part of the time stamp (BCD type) TS.year (WORD): year part of the time stamp (BCD type) 4 Status WORD The status of the DFB. The DFB has a TS buffer which can store up to 100 TS data. The data is stored in the buffer until the Ack is set to 1. D0~D7: Quantity of new TS in the DFB buffer D8: Buffer status 0 = Buffer empty 1 = Buffer overloaded 2 = Buffer not empty or overloaded 28
3-Design DFB2: TS_NTP Function: The TS_NTP DFB is designed for time stamping with NTP mode. It adds the time stamp to the event data with NTP time, and sends out the time stamps. With this function block, the user can choose the detection mode for time stamps This DFB also handles a buffer of up to 100 records of time stamped data. Data type: DFB type: TS_NTP DFB input/output types: 29
3-Design The next table gives parameter definitions: TS_NTP_DFB Input No Parameter Type Comment 1 Input TS_DDT_Input TS_DDT_Input.module (BYTE): inputs module number TS_DDT_Input.in (ARRAY[1..16] OF BOOL): 16 discrete inputs 2 Mode INT mode=1: TS with input Rising edge detection mode=2: TS with input Falling edge detection mode=3: TS with both Rising and Falling edge detection 3 Ack BOOL Acknowledgement of the new TS A Rising edge of Ack can trigger an acknowledgment of one TS. If Ack is set to 1, a new TS is always acknowledge. 4 Reset BOOL error reset, buffer reset Output No Parameter Type Comment 1 NTP_time Display_NTPC Display_NTPC.DT_Value: real RTC time and data Display_NTPC.Millisecond: real RTC ms 2 nd_ts BOOL nd_ts=1: New TS in the buffer nd_ts=0: The buffer is empty 3 Ts TS Time stamping struct: TS.in (WORD): D0~D5: the channel number of the discrete input D6, D7: the mode of the input. (01: Rising edge, 10: Falling edge.) D8~12: the module number of the input signal. TS.ms (WORD): ms part of the time stamp TS.hour_min (WORD): hour and minute part of the time stamp (BCD type) TS.month_day (WORD): month and day part of the time stamp (BCD type) TS.year (WORD): year part of the time stamp. (BCD type) 4 Status WORD The status of the DFB. The DFB has a TS buffer which can store up to 100 TS data. The data is stored in the buffer until the Ack is set to 1. D0~D7: Quantity of new TS in the DFB buffer D8: Buffer status 0 = Buffer empty 1 = Buffer overloaded 2 = Buffer not empty nor overloaded 30
3-Design DFB3: TS_ERT Function: The TS_ERT DFB is designed for reformatting ERT mode time stamps. It receives the time stamps and transforms the data to a format that can be received by SCADA. This DFB also handles a buffer that can store up to100 records of time stamped data. Data type: DFB type: TS_ERT DFB input/output types: 31
3-Design The following table gives parameter definitions: TS_ERT_DFB Input No Parameter Type Comment 1 nd_tt BOOL From the pin of the ERT nd_tt. Refer to ERT user manual 2 tt_data ERT_10_Ttag From the pin of the ERT tt_data. Refer to ERT user manual Output No Parameter Type Comment 1 nd_ts BOOL nd_ts=1: New TS in the buffer nd_ts=0: The buffer empty 2 Ts TS Time stamping struct: TS.in (WORD): D0~D5: The channel number of the discrete input D6, D7: The mode of the input. (01: Rising edge, 10:Falling edge) D8~12: The module number of the input signal TS.ms (WORD): ms part of the time stamp TS.hour_min (WORD): hour and min part of the time stamp (BCD type) TS.month_day (WORD): month and day part of the time stamp (BCD type) TS.year (WORD): year part of the time stamp (BCD type) 32
3-Design DFB4: TS_DataBase Function: The TS_DataBase DFB is designed for saving the time stampsed data. It is used in different time stamping modes and can save up to 100 time stamped records in the database. Data type: DFB type: TS_DataBase DFB input/output types: 33
3-Design The following table gives parameter definitions: TS_DataBase Input No Parameter Type Comment 1 ND_TS BOOL The new TS is saved in the DataBase 2 TS TS Time stamping struct: TS.in (WORD) D0~D5: The channel number of the discrete input D6, D7: The mode of the input. (01: Rising edge, 10: Falling edge) D8~12: The module number of the input signal TS.ms (WORD): ms part of the time stamp TS.hour_min (WORD): hour and min part of the time stamp (BCD type) TS.month_day (WORD): month and day part of the time stamp (BCD type) TS.year (WORD): year part of the time stamp (BCD type) Output No Parameter Type Comment 1 TS_DB ARRAY[0..99] OF TS Time stamping structure array: The time stamps database The length of the database is 100 2 DB_DPTR UINT It is a pointer in the Database that points to the TS which is sent to the Database when the SCADA is ready. 34
3-Design DFB5: TS_DataBase_To_VJC Function: The TS_DataBase_To_VJC DFB is designed to facilitate the communication tags between the PAC and Vijeo Citect SCADA. It allows the time stamping database to transfer from the PAC to Vijeo Citect in the asynchronous mode. It means that the time stamps which are recorded by the TS_DataBase DFB can be transferred to the Vijeo Citect one at a time in each communication cycle. It can save the communication tags between the PAC and the SCADA system. Data type: DFB type: TS_DataBase_To_VJC DFB input/output types: 35
3-Design The following table gives parameter definitions: TS_DataBase_To_VJC Input No Parameter Type Comment 1 DB_DPTR UINT It is a pointer in the Database that points to the TS which is sent to the Database when the SCADA is ready. 2 VJC_DPTR UINT It is the pointer to TS that is prepared to be sent to Vijeo Citect in the DataBase. If the VCJ_DPR is equal to DB_DPTR, it means all the TS in database have been transferred to Vijieo Citect 3 TS_DB ARRAY[0..99] OF TS Time stamping structure array: The time stamping DataBase Length of the database is 100 Output No Parameter Type Comment 1 In WORD Input signal (event data) for time stamped 2 Ms WORD ms of the time stamp 3 hour_min WORD hour and minute of the time stamp 4 month_day WORD month and day of the time stamp 5 Year WORD year of the time stamp 6 PAC_DPTR UINT It is the pointer to the TS array that needs to be sent to Vijeo Citect in the DataBase. It is sent to SCADA to control the communication cycle between PAC and Vijeo Citect SCADA 36
3-Design 3.4. SCADA design The Vijeo Citect time stamping genies are used to display the digital input signal with time stamps. Following is an example of using the genies with Vijeo Citect. The genies are named D_TS with the function named Timestamping_xxx(). The time stamps from the PLC will be displayed on the Vijeo Citect screen. 2 1 1. Add the genies named D_TS in the Vijeo Citect screen. The genies parameters include: Channel: Vijeo Citect internal tag, which is used to get the digital channel status from the PAC. TimeStamping: Vijeo Citect internal tag, which is used to get the digital channel and time stamping from the PAC. TextOff: customer remark when the channel is OFF TextOn: customer remark when the channel is ON 2. Add the function named Timestamping_xxx() in the Vijeo Citect screen. Timestamping_xxx( ) function design: Synchronize the cycle time between the PAC and SCADA to get the right time stamped data. The user needs to create three functions for each mode: RTC, NTP and ERT. 37
3-Design For example, the TimeStamping_RTC( ) function code is presented below: 38
3-Design This figure shows the time stamping genies in the RUN mode. Channel status Channel status Text 39
3-Design 40
4-Configuration 4. Configuration This chapter provides configuration methods according to the different time stamped solutions. 4.1. Time stamped by module There are three parts to configure the time stamped by module solution: the time reference device, PAC and SCADA. This configuration is implemented according to solution #2, refer to Table 3. Time reference device - set up GPS receiver Step Action 1 Put the GPS receiver module into the BBS-3 GPS, and connect the antenna. 2 Check if the synchronization is OK. 3 Set up the time synchronization module (DCF module). 4 Put the DCF77 module into the BBS-3 GPS and connect it to the ERT module for time synchronization. 41
4-Configuration PAC configuration Step Action 1 Mount the ERT modules on the Quantum rack. Note: The extension I/O rack cannot support the ERT module. 2 Set up the ERT module Input and Output Mapping. 3 Set up the ERT.Module.Clock to DCF/GPS-SYNC. 42
4-Configuration SCADA The example sets up the communication between the PAC and SCADA with OFS configuration tool. Step Action 1 Generate the.xvm file from the UnityPro project. 2 Set up a device named STG_TS in the OFS configuration tool. Import the.xvm file into device symbol file. 3 Set up the SCADA I/O device with the Express I/O Device Setup tool. Note: Select the OPC protocol as the communication protocol. 4 Set up the OPCAccessPaths in the Vijeo Citect.ini file. Make sure the value of the OPCAccessPaths is the same as the name in the OFS configuration tool. 43
4-Configuration 4.2. Time stamped by program There are three parts to configure for the time stamped by program method; the time reference device, PAC and SCADA. The example is implemented according to solution #3, refer to Table 3. Time reference device There are two parts to the time reference configuration, the GPS receiver setup and the time synchronization setup. Set up GPS receiver: Step Action 1 Put the GPS receiver module into the BBS-3 GPS and connect antenna. 2 Check if the synchronization is correct. Set up time synchronization module (NTP server): Step Action 1 Put the NTP server module into the BBS-3 GPS and connect it to the network for network time synchronization. 2 Set up the NTP server. For example, NTP server IP address is 192.168.0.6 Run the dnts3.exe with the following command to set up the NTP server IP address: dnts3 s 192.168.0.6 255.255.255.0 00-03-b9-a9-0b-9b 44
4-Configuration PAC Set the NOE module (NTP Client): Step Action 1 Set up NTP client IP address For example: NTP client IP address is 192.168.0.31 2 Set up the NTP client in the web page. 3 Log on the web server, and set up the NTP client. 45
4-Configuration SCADA This process is same as the one described in Chapter 4.1. 46
5-Implementation 5. Implementation 5.1. PAC This chapter helps user to implement the time stamping application with three different time stamping modes. It includes PAC programming and SCADA programming. There are two steps in the PAC programming: time stamping and sending time stamps to SCADA. Time stamping programming There are three modes for time stamping: RTC, NTP and ERT mode. Consequently there are three ways to implement the time stamping function: RTC mode: Use the TS_RTC DFB to generate the time stamping, and then use the TS_DataBase DFB to record the time stamp in the database. 47
5-Implementation NTP mode: Use the TS_NTP DFB to generate the time stamp, and then use the TS_DataBase DFB to record the time stamp in the database. ERT mode: Use the Quantum, DROP, and ERT_854_10 EFBs to set up the ERT module. Then use the TS_ERT DFB to generate the time stamp and use the TS_DataBase DFB to record the time stamp in the database. 48
5-Implementation Sending time stamps to SCADA Step Action 1 Create the eight tags as I/O variables between PAC and SCADA for each DB. DB1_xxx is for RTC mode, DB2_xxx is for NTP mode, and DB3_xxx is for ERT mode. Time stamps RTC mode sent to Vijeo Citect. Time stamps NTP mode sent to Vijeo Citect. Time stamps ERT mode sent to Vijeo Citect. 2 Use the TS_DataBase_To_VJC DFB to send the time stamps to SCADA. 3 Use the TimeStamping_xxx( ) function in SCADA to get the time stamps from the PAC. Note: TimeStamping_RTC( ) is for RTC mode, TimeStamping_NTP( ) is for NTP mode, and TimeStamping_ERT( ) is for ERT mode. 49
5-Implementation 5.2. SCADA There are three steps in the SCADA programming process: Step Action 1 Click on the D_TS genies icon and drag it to the location of the digital signal which needs to be time stamped. Then, define the signal on/off text in the D_TS genies. 2 Insert the timestamping_xxx( ) function in the SCADA: In the RTC mode, use TimeStamping_RTC( ) function. In the NTP mode, use TimeStamping_NTP( ) function. In the ERT mode, use TimeStamping_ERT( ) function. 3 Set up the digital alarm, if needed. Digital alarm configuration: 50
5-Implementation Alarm format configuration For example: DefDspFmt = {Desc,32}{Name,20} DefSumFmt = {Desc,32}{Name,20} 51
5-Implementation 52
6-Operation 6. Operation This chapter presents the results of the time stamping, which includes time stamping diagnostics and alarms. 6.1 Time stamping diagnostics In the time stamping genies dialog box, there are three sections on the page. The RTC_Mode time stamping column shows the time stamps that are generated with the RTC Mode. The NTP_Mode time stamping column shows the time stamps that are generated with the NTP Mode. The ERT_Mode time stamping column shows the time stamps that are generated by the ERT mode. There are 16 channels in each column. Figure 8 Time Stamping Genies Dialog 53
6-Operation 6.2 Time stamping alarms All of the channels are set to alarm. Regardless of whether the channel is ON or OFF, the time stamping alarm is recorded by SCADA. Figure 9 Time Stamping Alarm Box 54
7- HPP Example 7. Hydro power plant example The purpose of this chapter is to provide a sample case to guide the user in implementing time stamping in process automation using the methods discussed in the previous chapters. Take the hydro power plant application as an example. This chapter describes the hydro power plant application background, system architecture, PAC application, SCADA application, User operation and Device list. 7.1. Introduction to the hydro power plant process This section introduces the hydro power plant process system, which includes the scale of the plant and the control system used in the hydro power plant process. The hydro power plant scale The hydro power plant (HPP) can be divided into a micro HPP, a small HPP and a large HPP according to the electricity generated. Usually, the micro HPP generates up to 1 MW of electricity, the small HPP generates between 1 to 30 MW of electricity, and the large HPP generates more than 30 MW of electricity. The following picture illustrates the different sizes and locations of the hydro power plants (HPP). Figure 10 Hydro Power Plant categories The hydro power plant process control system 55
7- HPP Example The hydro power control system includes the main machinery and an auxiliary equipment system. Main machinery system: It is composed of a turbine, generator, speed controller and exciter system. The turbine transforms the water s potential energy into mechanical rotational energy. The turbine drives the generator. The generator transforms the mechanical energy into electrical energy. A speed controller ensures the balance between the output of turbine and the load of the generator, and ensures that the turbine rotates at a certain speed (frequency). The exciter system transforms the output of generation into DC power by exciting the transformer and the semiconductor rectifier. Auxiliary equipment system: This is composed of the water supply, a substation, the oil supply and a compressed air system. 7.2. Application background In the hydro power plant, the time stamping application displays and records the status changes of the turbine and the generator. Figure 11 shows the time stamping application process in hydro power plants: Figure 11 Time stamping application in HPP system A large hydro power plant requires high reliability and high performance. The Quantum platform with ERT mode is best choice for it. Small and micro hydro power plants require flexibility and are cost sensitive. Premium or M340 platform with NTP or RTC is suitable for them. 56
7- HPP Example 7.3. System architecture The following is a detailed diagram of the system architecture of the time stamping solutions in the hydro power plant. In this STG, two kinds of time stamping solutions are offered: time stamped by program and time stamped by module. Time stamped by module (ERT mode): An example of a hardware system using the time stamped by module (ERT mode) Figure 12 System architecture of time stamped by module 1. Clock reference acquisition GPS receiver with the DCF 77 unit synchronizes the Quantum 140 ERT 854 10 module time clock. 2. Time stamped on the event data The Quantum PAC with the ERT module generates the time stamped data. 3. Monitoring & data inquiry 57
7- HPP Example SCADA can be used to display the different applications with time stamping, such as SOE or digital alarms. Time stamped by program (NTP mode): There are three parts to the system architecture, which include clock reference, input data with time stamping and monitor & data inquiry. 7.4. PAC application Figure 13 System architecture of time stamped by program 1. Time clock acquisition A GPS receiver with the NTP server provides the NTP server clock for time stamping. 2. Time stamped on the event data An M340 PAC with the input module generates the time stamping data. (FAST task should be set up to improve the time stamped accuracy.) 3. Monitoring & data inquiry SCADA can be used to display the different applications with time stamping, such as SOE and time stamping alarms. A PAC program comprises the following main sections: turbine & generator start process, turbine & generator stop process, NTP stamping mode and ERT stamping mode. Two different stamping modes are used to tag the sequence events of the turbine and generator start and stop processes. 58
7- HPP Example The architecture of hydro power start and stop processes is programmed with the time stamping application as follows: Next are the details of the main sections: Turbine & generator start process section The SFC programming language is selected to manage the start sequence of the related equipment in the hydro power plant, which includes H_Start1, H_Start2 and H_Start3. Turbine & generator stop process section The SFC programming language is selected to manage the stop sequence of the related equipment in the hydro power plant, which includes H_Stop1, H_Stop2 and H_Stop3. NTP stamping mode section Use this section to generate the time stamping with NTP clock. Meanwhile, users can manage the time stamping storage and send the time stamp to the SCADA system. ERT stamping mode section 59
7- HPP Example Use this section to get the time stamping from the ERT module. Meanwhile, users can manage the time stamping storage and send the time stamp to the SCADA system. In order to set up the program easily, there are two methods to help users use the five DFBs in a hydro power control program. Method1: Import the DFB (***.XDB file) from its directory, including TS_DataBase_To_VJC, TS_DataBase, TS_RTC, TS_NTP and TS_ERT. Users can follow the STG implementation in the PAC section to set up the time stamping application with the DFBs. See section 5.1. Method2: import the sections (***.XBD file) from its directory. There are two sections for the time stamping, which include the TS_NTP_Mode.XBD, and TS_ERT_Mode.XBD. 7.5. SCADA application The hydro power time stamping application can be controlled and monitored with Vijeo Citect SCADA. Please refer to Chapter 5 regarding the application of the time stamping genies and alarms. 7.6. User operation The hydro power time stamping application has four interfaces: 60
7- HPP Example Hydro power main control system Stop status to generation status process Generation status process to stop status Time stamping database The hydro power main control system includes the turbine and generator control monitor, oil supply system status monitor and water supply system status monitor: Figure 14 HPP main control system The turbine and generator from stop to generation status interface can monitor the sequence and status of equipment. D_TS genies are put beside the corresponding steps, and can display the signal text and the event time. RTC mode, NTP mode and ERT mode all can be used. This helps user to manage the work process. Figure 15 Turbine&Generator Stop to Generation Process 61
7- HPP Example The turbine and generator emergency stop process interface can monitor the sequence and status of equipment. D_TS genies are put beside the corresponding steps, and can display the signal text and the event time. RTC mode, NTP mode and ERT modes all can be used. This provides the user with a way to manage the work process. Figure 16 Turbine Emergency Stop Process 62
7- HPP Example 7.7. Device list The following chart shows the device list for the time stamped by module and time stamped by program methods: Figure 17 Device List of time stamped by module 63
7- HPP Example Figure 18 Device List of time stamped by program 64
Appendix Appendix Abbreviations CPU Central Process Unit DCF77 Longwave time signal and standard-frequency radio station DFB Derived Function Block ERT Shortened name for the Quantum 140 ERT 854 10 module GPS Global positioning system I/O Input and output NTP Network Time Protocol PAC Programmable Automation Controller RTC Real Time Clock SCADA Supervisory Control and Data Acquisition SOE Sequence of Event 65
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