1. Copyright2013-2014
PROJECT REPORT
Project Title: DCS Panel Design
Organization: TOSHIBA JSW Power
Systems
By: Prakul Julka
EIC (2012-16)
101205048

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ABOUT TOSHIBA JSW Power Systems
DEALS IN POWER SYSTEM DESIGN ENGINEERING
MAINLY INTO DCS PANEL DESIGN
HAVE 4 ENGINEERING DEPT.:- MECHANICAL
- CIVIL
- ELECTRICAL
- CONTROL & INSTRUMENTATION

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ABOUT DCS
• An advanced control strategy.
• Mainly used in Industrial Automation.
• Control System for process plant

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EXAMPLE SCENARIOS WHERE A DCS
MIGHT BE USED INCLUDE
• Petrochemical (oil) and refineries
• Pulp and Paper Mills
• Boiler controls and power plant systems
• Nuclear power plants
• Environmental control systems
• Water management systems
• Metallurgical process plants

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POJECT
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ANPARA THERMAL POWER PLANT SYSTEM
UPGRADATION PROJECT

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PROJECT FLOW PROCESS
• PANEL INTEGRATION
• HMI SETUP & TESTING
• CONTROL LOGIC SEQUENCE DESIGN
• GRAPHIC DESIGN
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FILE TRANSFER PROTOCOL
ADOPTED
• ETHERNET : For transfer of data between
HMI and Panel
• DEVICE-NET: For protocol conversion.
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PANEL INTEGRATION
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FRONT REAR

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ACTUAL PANEL AFTER
INTEGRATION
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CPU
PIFL
POWER SUPPLY
I/O CARDS

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CONTROLLER MODULE (CPU)
• MAIN PROCESSING UNIT
OF THE PANEL
• CONNECTED TO HMI FOR
SYSTEM UPDATION
• WORKS ON LINUX OS
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PROTOCOL CONVERTOR (PIFL)
• USED TO CONVERT ONE
TRANSFER PROTOCOL TO
ANOTHER.
• IN THIS PROJECT, ETHERNET
TO DEVICE-NET
CONVERSION IS USED
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PROFIBUS PORT

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I/O CARDS
• USED TO AQUIRE AND SEND DATA FROM AND TO THE FIELD
• INPUT OUTPUT OPERATION IS CONTROLLED BY CPU.
• SIGNAL AQUIRED: ANALOG AND DIGITAL BOTH
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OVERALL SYSTEM ARCHITECTURE
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TESTING
HARDWARE TESTING
• CONTINUITY TESTING
• MEGGER TESTING
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SOFTWARE TESTING
• I/O TESTING
• RAS TESTING
• DAS TESTING
•PERFORMED AFTER PANELS ARE ASSEMBLED
•CLASSIFIED INTO TWO TYPES

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HARDWARE TESTING
CONTINUITY TESTING
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MEGGER TESTING

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SOFTWARE TESTING
• THREE TYPES OF TESTING PERFORMED ON PANEL THROUGH
TOSMAP-DS (SOFTWARE DESIGNED BY TOSHIBA)
-I/O TESTING
-RAS TESTING
-DAS TESTING
• ALL THE ABOVE TESTING ARE PERFORMED ON ESSEMBLED
PANEL LINKED TO HMI SYSTEMS
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SOFTWARE TESTING
RAS TESTING: Reliability, Acceptability, and Serviceability
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SOFTWARE TESTING
DAS TESTING: Data Acquisition System
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ALARM MONITER
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SOFTWARE OVERVIEW:TOSMAP-DS™
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SOFTWARE OVERVIEW:TOSMAP-DS™
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IEC LAUNCH SCREEN TOSMAP BOOT MENU

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CONTROL LOGIC DESIGN
• DESIGNED USING EDITOR MENU OF TOSMAP-
DS™
• LOADED INTO CPU ON THE PANEL FROM HMI.
• CONTROLS THE INPUT/OUTPUT SEQUENCE OF
THE SIGNALS
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PROCESSES INVOLVED IN LOGIC
DESIGN
• I/O LIST PREPRATION
• CREATING TAG DATABASE
• REFERENCE LOGIC REVIEW
• LOGIC DESIGN
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I/O LIST PREPARARION
• PREPARED IN MS EXCEL
• MAIN AIM IS SIGNAL GROUPING
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LOGIC GENERATION
• PREPARED IN LOGIC EDITOR ON TOSMAP-DS™
• LADDER LOGIC TYPE INTERFACE
• AND/OR LOGIC PROGRAM
• BLOCKS USED ARE GIVE BELOW.
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MACROS
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•USED TO CONTROL FEEDBACK
OPERATION
•SIMILAR TYPE OF FEEDBACK SIGNALS
ARE GROUPED TOGETHER.

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GENERATED LOGIC SAMPLE
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GHRAPHICS DESIGN
• GRAPHICS PROVIDE REMOTE ACCESS TO VARIOUS PROCESSES
EQUIPMENT IN THE PLANT.
• BASICALLY A USER INTERFACE SYSTEM.
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GRAPHIC TOOL
• ALLOW CONSTRUCTION/MODIFICATION OF THE USER
INTERFACE SYSTEM
• AN EFFICIENT WAY TO CREATE AND MODIFY GRAPHIC
DISPLAYS.
• POWERFUL DRAWING FUNCTIONS.
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GRAPHIC EDITOR WINDOW
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Work Space
Editable for each
symbol parameter
Symbol palette
IEC LAUNCH SCREEN GRAPHIC EDITOR

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SAMPLE OF DESIGNED GRAPHICS
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LINKING GRAPHICS AND LOGICS
• TAG DATABASE IS FEEDED IN BOTH GRAPHICS AND
LOGIC FILE
• BACKUP IS TAKEN IN A HARD DRIVE AND FED IN TO
THE CONTROLLER
• THE PANEL IS POWERED AND READY TO BE TESTED
ON THE SITE.
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33. Copyright2013-2014
THANK YOU
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