1. Colorado Energy Nations
-:-
Boiler 5 Flame Safety
-:-
Norpak to ControlLogix Translation
-:-
1JEROME-AXEL CAIN 11-NOV-14

2. Boiler 5 Flame Safety – Norpak to ControlLogix Translation
Table of Contents
 Programming Approach
 What is Norpak ?
 Why Allen Bradley’s ControlLogix Platform ?
 Programming Philosophy
 Conclusion - Q&A
2JEROME-AXEL CAIN 11-NOV-14

3. Boiler 5 Flame Safety – Programming Approach
Why start from scratch with:
 Existing Controls ViewPoint Narrative
 Existing Norpak Logic
→ Methodology used successfully 3 times for the Flame Safety
Upgrades on our other Boilers.
3JEROME-AXEL CAIN 11-NOV-14

4. Boiler 5 Flame Safety – What is Norpak ?
 Transistorized solid state control components system
 Introduced in the late 1950s
• Very reliable
• Obsolete
• No comms to SCADA
 Cannot accommodate expansion for natural gas logic
 Based on NOR (Not – Or) logic
• NOR, OR gates
• TON timers
• Transfer elements (one shot pulse generators)
4JEROME-AXEL CAIN 11-NOV-14

5. Boiler 5 Flame Safety – Why Allen Bradley’s ControlLogix ?
 Platform already operating in our plant
• Steam Turbine & Generators Controls and CEMS system
• RSLogix5000 License already acquired
 Personnel familiar with RSLogix5000
• Easy to troubleshoot
• No training needed for Techs
 Platform works well with iFIX 5.1 SCADA
• No need to acquire new driver
• IGS driver will function with 1756-L71 thru L75 processors up to firmware version 20.11
5JEROME-AXEL CAIN 11-NOV-14

6. Boiler 5 Flame Safety – Programming Philosophy
 1 Sheet of Norpak = 1 Function Block Diagram Routine (1 or 2 sheets)
• Blocks named according to NORPAK
• Lay-out is kept similar
• Some blocks might be merged (especially ORs)
 Existing Instructions logically equivalent to Norpak Blocks
• Boolean OR (BOR)
• Boolean AND (BAND) to reflect some contact in series
 Add-on Instructions logically equivalent to Norpak Blocks
• NOR with 1, 2, 3, 4, 6, or 8 inputs and 1 output
• TON timers with 1 logic input, 1 preset input and 1 done output
• XFER_PULSE with 1 logic input, 2 control gate inputs and 2 outputs
6JEROME-AXEL CAIN 11-NOV-14

7. Boiler 5 Flame Safety – Conversion Example
7
Digital AC Input
“A” Soot Blowers Run Status
AC to DC transformer
(no logic change)
1 in NOR_117C
becomes
NOR1_117C
TON timer 108
becomes
NP_TON_108
1 in NOR_117D
becomes
NOR1_117D
Bit ASB on wire 1330
is logically equivalent to
NOR1_117D.Out9
Turns ON when A Soot Blowers start running
Turns OFF 20s after A Soot Blowers stopped
NOR1_117D.Out9 can then be called up in
the routine SHT42 and SHT60
JEROME-AXEL CAIN 11-NOV-14

8. Boiler 5 Flame Safety – Programming Details
 Wiring between blocks is checked vs. Norpak Sheet
 Symbols, Comments, Descriptions are used enthusiastically
 Program is up and Running
• Norpak Sheet 35 through 35 have been translated
• Translated logic has been successfully tested with the RSLogix5000 emulator against the
Controls ViewPoint narrative
‒ Use of Test Routines
‒ all relevant Inputs are displayed and toggled
‒ behavior of internal and output bits is checked against narrative
 Logic can be easily modified / expanded
• If required for NFPA compliance
• To accommodate new natural gas inputs, circuits and outputs.
8JEROME-AXEL CAIN 11-NOV-14

9. Boiler 5 Flame Safety – Conclusion
 Conversion Completed
 A way forward with an established framework
• New natural gas logic in development
• To be expanded for natural gas logic and I/Os
• New PanelView Plus screens in development
 Questions ?
9JEROME-AXEL CAIN 11-NOV-14