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Control & HMI Emulation Project

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This presentation provides a real world example of replacing a hardware based RTA card with an emulation solution.

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Control & HMI Emulation Project

  1. 1. info@gses.com Control & HMI Emulation Project
  2. 2. 2 Part 1 The Project Rick Baker – Exelon - Quad Cities
  3. 3. 3 Plant ABB Advant System (Generic diagram, newer equipment)
  4. 4. 4 Advant Controller AC450
  5. 5. 5 AS500 OS HP Visualize B2000 • Unix running HP-UX 10.20 OS • Limerick had newer B2600
  6. 6. 6 ABB Advant Keyboard
  7. 7. 7 PCI-Based RTA Card
  8. 8. 8 FW HMI Screen
  9. 9. 9 RCS HMI Screen
  10. 10. 10 Simulator Needed to Emulate AC450 and Stimulate AS500OS HMI • Plant code and database received from plant • Code and DB transformed into RTA card compatible version • AS500OS HMI slightly modified for simulator use –ATS link software installed • Four main components installed on simulator model computer(s) –developed for WindowsNT • PCI-based RTA card installed • ATS Link setup to communicate with AS500OS HMI
  11. 11. 11 Upgrade Requirements Last 15+ Years • Simulator model PC refreshes – required large PCI slot • Microsoft OS upgrades to Windows 2000, Windows XP – Windows XP version started to become unstable – Needed to get to Windows 7 • RTA card driver not compatible with W7 or newer OS’s • No practical solution from ABB/Westinghouse – Rumors of a USB version
  12. 12. 12 Additional Issues and Needs • AS500OS HMI B2000 and B2600 are obsolete • Repurposed HP C3600 – Acquired from retired plant system • Preference was for non-hardware solution – Allow for better use of glass simulators and V-panels – Eliminate PC hardware platform requirements – PCI slot • RTA Card replacement cost was very high – Were able to acquire RTA cards from OEM vendor – Future availability uncertain
  13. 13. 13 Part 2 The Team Scott Zepplin – GSE Systems, Inc.
  14. 14. 14 Contract • Overall Contract awarded to GSE • Sub-contract awarded by GSE to nHance Technologies
  15. 15. 15 Project Roles: GSE Systems, Inc. • Overall project management • Configuration Control • Interfacing between nHance solution and Exelon loads • Factory acceptance testing • Site integration
  16. 16. 16 Project Roles: Exelon • Data collection • Provide operational systems for nHance • Site acceptance testing • Configuration control –Fleet-wide project management –Fleet-wide design decisions
  17. 17. 17 • Control System Translation • HMI Emulation • Configuration Control • Alarm Manager Solution • Keyboard Solution • Site Integration Project Roles: nHance Technologies
  18. 18. 18 Fleet Solution Advantages • Testing was done for each site individually • Each site took a slightly different approach to the testing • As issues were identified at each site, the resolution was rolled out to all 3 sites • Resulted in better overall product
  19. 19. 19 Part 3 The Solution Todd Sneed – nHance Technologies
  20. 20. 20 nHance Technologies Solution Details • Configuration Management • DCS Emulation • Control System Emulation • DB Elements • PC Elements • HMI Emulation • Custom Screens • Standard Screens • Keyboard Solution
  21. 21. 21 Configuration Management • Ensure model and HMI updates synchronized across 3+ locations – nHance Office – GSE St Marys and/or Sykesville Office – Site • Required Distributed Version Control System – Does not restrict/preclude using server based VCS eg SVN – Secure HTTPS / SSH Transmission protocol • ‘git’ hosted on nHance private servers – Required 2 repositories, one for Model, one for Program / project files • Workflow – nHance Review/Make Changes … Push up to nHance Cloud Server – GSE Pull Down latest rev for testing pre-FAT – Site Pull Down for install at site
  22. 22. 22 Control System Overview ABB Advant Control System Overview – PC Program – Main Control Logic Program • Complex Cycle Logic 3 “Interpreters” • PC Elements – Individual Function Blocks (eg. AND/OR/PID, etc.) • PC Elements can be Scheduled in any Interpreter / Rate group/ Order within rate group • Entire blocks of logic and be dynamically bypassed – “Database” or DB Elements • Typical “Tags” • Interface between PC Program and external world • Some “logic” eg. Block functionality/ Limit Checks • I/O interface / Modbus / Profibus interface
  23. 23. 23 Control System Emulation Translation Approach – C++ Program developed to read in DB and PC Element configuration files – Automatically links function blocks and DB Element names – Automatically creates Simulator database .ADD files – Automatically creates Simulator I/O list – Optionally match I/O tag names to Process model variable list (if provided) to link I/O points to process model variables – Generates Fortran Source code with comments – Maintains left-over time to cycle control exact number of times required (eg. 20ms rate group cycled correctly with 50ms time step size). – Separate schedule for DB point processing and PC Cycle time execution – Completely automatic, no human intervention required
  24. 24. 24 Control Cycle Overview
  25. 25. 25 Control System Emulation – Alarm Manager Alarm Manager – Maintains list of points in alarm and alarm acknowledgement state – ABB Advant System Extremely flexible in alarms/events – Alarm/event configuration files not available on simulator RTA card workstations – Point can be have an alarm and an event at same time – All three sites used different approaches to alarms and events
  26. 26. 26 HMI Emulation Translator Approach – Automatically read in HMI Configuration files and generate visual basic source code to create HMI executable – HMI Graphics files a derivation of Sherrill-Lubinski Graphical Modeling System (SL-GMS) – static graphics only • References system objects and custom objects with scripting functionality – Each HMI screen required both graphic files and scripting files to tie point names/scripts to dynamic objects – VB classes created by hand for system objects (eg. Dialogs)
  27. 27. 27 • Alarm Screens – Alarm List – Event List – Last unacknowledged Alarm in Header • Trend Screen – Unique Trend Control scrolling – Rich Feature Set (not all supported) • Dialog Boxes – Navigation – Unique per Point Type • Display Menu HMI Emulation Standard Screens
  28. 28. 28 • ABB Advant Keyboard Overview – Complex device with normal keyboard + several custom keys – External power supply – Typical USB connection to HP unix workstation – Mouse attached to keyboard • Sort of worked on PC – Normal PC keys worked – Custom keys mapped to existing PC keys, some did nothing – Mouse just worked • USB Sniffing tools revealed – Keyboard was USB hub + 3 HID devices, 2 keyboards one mouse • WireShark USB Pcap used to inspect HID USB keys – Keyboard hook used to “consume” the key from that specific USB device – Device ID’s changed when computer reboot Keyboard Interface Solution
  29. 29. 29 • Keyboard – Solution not perfect, but adequate • Alarms/Events – Point can be in Alarm and Event at same time – Several instances of same Alarms on Alarm List – Event Treatment pointers configuration could not be found • Trend Control – Unique trend scrolling and several different features could be supported • SL-GMS – Some commands not easily handled in VB (eg. Gradients fills) – Transforms Project Challenges
  30. 30. 30 • Stimulated System was not “gospel” – Plant Control logic manipulated before installed on RTA – AI points converted to AIC – ERR Flags for some AIC points were Set by ??? – Caused translator to set error flags for AIC points which proved incorrect – Caused translator to set error flags for AI Points which proved incorrect – Model AI Deadband Logic – Removed as part of removing stimulated interface – Contributed to differences and repeatability issues on RTA load • Sometimes the “simple” blocks aren’t so simple – MAJ-R Majority Selector • All-In-One design of HMI – Avoided need screen-to-screen communication – Proved to be sluggish on loading screens especially on Windows 7 Solution Lessons Learned
  31. 31. 31 Project Results - Lessons Learned • Relieved hardware platform requirements – PCI slot for RTA card • HMI runs on standard Windows 7 PC – Needs to be fast to prevent delays when Operator switches displays • Relieved OS requirements • VB6 required for displays – Newer version would have been preferable
  32. 32. 32 Project Results - Lessons Learned (cont.) • Relieved frequent issues where the RTA cards would not function correctly – (loss of comm., locked up, misc.) • Original simulator version didn’t exactly match plant implementation – Discovered issue with analog inputs range treatment – Error flags being set that would not in the plant • causes a different response on some transients
  33. 33. Thank you. For more information, go to: www.GSES.com info@gses.com Or call 800-638-7912