PLANT INFORMATION SYSTEM.ppt

Development of Plant Information
System for Nuclear Power Plant
Sachin Kumar Patidar
MS By Research (CSE)
Reg. No. 01051882
Presentation
On

Problem Statement
 Generation of power from Nuclear power plants needs close monitoring of
various safety parameters such as temperature, pressure, and Heavy water
loss. The Data acquired from the plant plays a pivotal role in deciding the
safety of the nuclear power plant.
 Manual data acquisitions is a time consuming process
 In order to know the Trends of the various points one had to plot the values
on the paper and see the trend at a particular channel .The availability of the
information was confined to the place where recording was made
 In this current project Windows was used in the acquisition of various signals
from the field of the nuclear plant. The Acquired data trends had been
displayed using Graphical Trend, Tabular Trend, Bar Graph, Mimics Display,
CTM Matrix, History, Alarm History, Summaries, Event Sequence Recording,
Disturbance recording and analysis, etc

Topics Covered
 Introduction to Data Acquisition System
 Introduction to Plant Information system
 System Analysis
 System Design and Implementation
 System Integration and Testing
 Results
 Conclusion
 Further Enhancement

Introduction to Data Acquisition System
A data acquisition system is a collection of hardware and
software that connects to the physical world. A typical data
acquisition system consists of these components:
 Data acquisition hardware.
 Sensors & actuators.
 Signal conditioning hardware.
 The computer.
 The software.

Block Diagram of Data Acquisition System

Introduction to Plant Information System
 The Plant Information System (PIS) is an Integrated Data
Acquisition and Operator Information System with a user-
friendly GUI software
 This is an information management system for effective
maintenance of the plant by integrating
 Data Logger System
 CTM Logger System
 Process Disturbance Recorder
 Event Sequence Recorder
 Central Monitoring Station Servers
 Display Stations

System analysis
 Plant Information system (PIS) is a High-speed Data
Acquisition System, which monitors and records
various parameters important to Plant’s safety and
Operation.
 The recorded information is used to analyze/ study
the important parameters of a plant disturbance
where pre disturbance and post disturbance data are
required.

The Main Functions OF PIS
 Collection of Raw Data by Data Logger, PDR, ESR Node and CTMLS Nodes.
 Linearization and Engineering conversion
 Alarm Detection and Display
 Display Formats – Textual and Graphical, CTM Matrix
 Editing and updating Server Database
 Broadcasting latest data to DS Nodes.
 Print Functions
 Time Synchronization
 Server Redundancy
 Fault diagnostics
 Special functions initiated by operator
 History and Summary
 Disturbance Recording
 Event Sequence Recording

PIS Compromises of
 IO Systems (DLS, CTMLS-1 & 2, PDR, ESR)
 Central Monitoring Station Servers(CMSSERVER-1 & 2)
 Display Stations(DS-1, DS-2, DS-3)
 Dual Ethernet Network(SW-1 & 2)

Event Sequence Recorder
Infrastructure Requirement
 ESR I/O controller, an Industrial grade Pentium-IV PC with a PCI Controller board,
and network interface ports
 I/O Bin with mother board, four 32-Channel Analog Input boards, and an I/O
Interface board
 A dedicated online printer
 Interconnecting cables and passive interface boards
Functional Requirement
 Scanning of 128 digital Input
 Every Second Send data to server
 Create Disturbance Record when disturbance Occur and send trigger event to PDR
 Print Events
 Records Events
Performance Requirement
 5 samples shall be average at every 100 millisecond and recorded

Process Disturbance Recorder
 PDR I/O controller, an Industrial grade Pentium-IV PC with a PCI Controller board, and
network interface ports
 I/O Bin with mother board, Five 32-Channel Analog Input boards, one 32-Channel
Digital Output board and an I/O Interface board
 Scanning of 128 Analog Input
 Drive 32 Digital Output
 Create Disturbance Record when receive disturbance trigger Event
 5 samples shall be average at every 100 millisecond and recorded

Channel Temperature Monitoring Logger System
 CTMLS I/O controller, an Industrial grade Pentium-IV PC with a PCI Controller board,
and network interface ports
 I/O Bin with mother board, Eleven 32-Channel Analog Input boards, one 32-Channel
Digital Output board and an I/O Interface board
 20 samples shall be average at every 5 second and recorded

Data Logger System
 DLS I/O controller, an Industrial grade Pentium-IV PC with a PCI Controller board, and
network interface ports
 I/O Bin with mother board, sixteen 32-Channel Analog Input boards, three 32-Channel
Digital Input boards, one 32-Channel Digital Output board and an I/O Interface board
 Scanning of 96 Digital Input
 5 samples shall be average at every second and recorded

Server and Display Unit
 Pentium-IV 3.2GHz PC
 512MB RAM
 160GB HDD
 High-resolution 19” TFT LCD Monitor
 Keyboard and Mouse
 Network Interface boards

Server and Display Unit Contd…
 Graphical Trend Display
 Tabular Trend Display
 Bar Graph Display
 ESR Inputs Display
 Analog Inputs Display
 Digital Inputs Display
 Configuration Display
 Mimics Display
 CTM Matrix Display
 Disturbance Recorder Display
 Alarm Page and Alarm History Display
 ESR Alarm History Display
 Maintain Database
 Printing of various Displays and Alarm Printing
 Processing
 History Recording
 Sending and receiving of information from various
nodes

Server and Display Unit Contd…
 Response time should not be more then 1 sec

Other Functional Requirement
 Time Synchronization with Master Clock
 Server Redundancy
 Operational Requirement
 Maintainability Requirements
 Reliability Requirements
 Security Requirements
 Testability Requirements
 Self-Diagnostics

Interface Requirement
Hardware Interface
 Printers
 PCI to IO Interface Board
 PCI Controller Board
 Analog Input Board
 Digital Input Board
 Digital Output Board
 Dual Ethernet
Software Interface
 Windows 2003 Server for Server
 Widows 2000 Professional for IO
 Windows XP for Display Station
 VC++.Net
 WIN 32 and MFC Libraries
 MS SQL Server 2000
 TCP/IP Protocol

System Design and Implementation
The major sub-systems required to fulfill the requirements are:
 I/O sub-system for scanning the field inputs and setting the
digital/analog outputs.
 Server for data storage, processing, controlling of network, centralized
logging and User Interface for Operator.
 Display Station for operator
 Printers for printing alarms, and operator demanded reports.

System Architecture
I/O
subsystems
Servers
Administrator’s Interface
Alarms,
Displays
and
Reports
Raw data
Field data
I
N
P
U
T
S
O
U
T
P
U
T
S
USER INTERFACE
Maintenance & Self Test
Operator’s
Interface
Display Stations

IO Systems
The basic functions performed by the I/O subsystems are as follows:
 Scanning the data (analog and digital) from the field.
 Transmission of raw data to Recording Unit.
 Recording the inputs sequentially.
 Quality checking of signals.
 Sending data to servers
 Synchronizing to the central clock system.
 Send health packets to server regularly.

Servers System
The functions of the Server Systems are as follows:
 Control of network traffic.
 Regularly transmitting and receiving the health packets to/from
standby server and other nodes over the network.
 Receiving the various queries and processing these and sending
back the required data to the nodes.
 Updating/maintaining dynamic database including history of
data, alarm pages, alarm history etc.
 Processing of analog/digital/calculated variables.

Display Stations
The functions of the Display Station are as follows:
 Maintain latest dynamic data, alarm pages, alarm history.
 Send health packets to server regularly.
 Maintain display (temporary) groups generated by the operator.
 Based on the operator’s request, it displays the current data taking from
display node itself up to 8 hrs and for history beyond 8 hrs, on day basis
it sends request to server and gets relevant data from server for
displaying.
 Various operational interactions will be carried out through the dialog
boxes, which will be through any one of the display nodes.

Printers
Printers are used to print alarms, and operator
demanded reports. All the printers in the PIS are
network printers and are connected through print
servers. But few of them are dedicated to
Supplementary Control Room and head-office of
NPCIL, Mumbai.

Software Design
PIS consist of software modules corresponding to I/O Systems
and Server/Client. Three-tier architecture is followed to develop
the software for entire PIS.
I/O Software
Server Software
Client Software

Io Software
ProcessHealthEvent
LanHealthEvent
Scanner
PISManager
PISIO NetComm
Shared Memory
TimerEvent
I/O System Intra Process Interactions

Io Software contd….
Updates Static data
Opens
Health Event Health Event
PIS
Manager
Scanner
PIS IOLanComm
Sends Health Data
Creates
Receives Query
From Servers
Sends I/O Data to
Servers
Reads I/O Data, and
Packs it
Shared
memory
Acquires Field
Data
Launches
Opens
Launches
Recevives Time Synch
Signal
Write I/O Data
Receive Health Query from
Server
I/O System Inter Process Interactions

Server Software
TimerEvent
ProcessHealthEvent
LanHealthEvent
PISProcess
PISManager
PIS NetComm
Shared
Memory
UpdateEvent
TimerEvent
OPTASK
DBUpdateEvent
TimerEvent
Server System Intra Process Interactions

Server Software contd…
PIS
Proces
s Netco
m
PIS
Manage
r
Optas
k
Send Health Request
Receive Health Status
Shared
Memory
Timer Events
Raw Process Health Events
Updates the Displays
Sends Alarms to
Alarm Print Server
Updates Alarm
Queues
Read IO Data
Update
IO Data
Reads Alarm Queues
Send I/O Query and
static data to IO
Reads Dynamic Data
Collects History,
alarms, ESR Event
Files
Update DB
Send Dyn and
Static Data to DS
Receive IO Reply
Receive Static data
from Server & DS
Server System Inter Process Interactions

Client Software
TimerEvent
ProcessHealthEvent
LanHealthEvent
PISProcess
PISManager
PIS NetComm
Shared
Memory
UpdateEvent
TimerEvent
OPTASK
DBUpdateEvent
TimerEvent
Client System Intra Process Interactions

Client Software Contd…
PIS
Process
Netcom
PIS
Manager
Optask
Send Health Request
Receive Health Status
Shared
Memory
Timer Events
Raw Process Health Events
Updates the Displays
Sends Alarms to Alarm
Print Server
Updates Alarm
Queues
Read IO Data
Update
IO Data
Reads Alarm Queues
Send I/O Query and
static data to IO
Reads Dynamic Data
Collects History, alarms,
ESR Event Files
Update DB
Send Dyn and Static
Data to DS
Receive IO Reply
Receive Static data
from Server & DS
Client System Inter Process Interactions

PIS manager
 Health Query Thread
 Health Reply Thread
 Process Monitoring Thread
 Time Synchronization Thread
 Redundancy Thread
 PIS manager View

PISIONetComm
 IO Reply Thread
 Static Data Receive Thread

Scanner Process
 Scan Thread
 Process Thread
 Record Thread

PISNetComm
 IOCommThread
 DSDynSendThread
 DSDynRecvThread
 DSDBSendThread
 DSDBRecvThread

PISProcess
 AlarmThread
 ProcessThread
 RecordingThread
 RecyclingThread
 Print Thread
 DR Collection Thread
 AlarmPrintThread

Optask
 Optask provides interface that takes advantage of the
computer's graphics capabilities to make the program
easier to use.
 Graphical User Interfaces of PIS can free the user from
learning complex Analysis of the data presented to him
in numerical form .
 Operator can get a clear picture about the functioning
of the subsystems in pictorial form rather than showing
him with the numerical values.
 User friendly graphical displays have been provided in
Plant Information System.

System Integration and Testing
 Unit Testing
 White Box Testing
 Black Box Testing
 Inheritance Testing
 Integration Testing
 Validation Testing
 System Testing

Conclusion
 The “Plant Information System” project was successfully developed, tested and
commissioned at Madras Atomic Power Station, Kalpakkam.
 We achieved the real time performance of scanning digital inputs in one millisecond.
And we developed the project without using any third party tools.
 We have used IO System for data acquisition and Acquired data is processed and
displayed at Server and Display station using neatly built Graphical User Interfaces.
 Some part of the “Plant Information System” is also ported in to Linux environment
including writing device driver for PCI board and IO boards, and IO software for Data
Acquisition at IO Nodes.
 The “Plant Information system” project development has given exposure in working
with the live environment following the Software Engineering Standards. This project
development has given an opportunity to gain more technical knowledge, working with
data Acquisitions of analog and digital inputs with a lower scan rate with real time
performance.
 This work has given the confidence and incited interest to work more on this kind of
projects. We have successfully implemented the user requirements and looking forward
for working on the future enhancements.

Further Enhancement
The following processes are under the consideration for the inclusion.
 This can be further enhanced to multi cards across multiple bins.
 We can extend this for network applications in a Distributed environment.
 We can also develop other types of graphical displays
 We can also use database for storing the acquired Dynamic data.
 Real Time Operating System like QNX or RT Linux can be used to acquire data
within microseconds and also to meet deadlines.
 Artificial intelligence can be included to analyzing and providing user guidance to
monitor the power plant.
 The Software can be ported in QNX or RTLinux to achieve real time performance

References and Bibliography
Books
 Programming Windows with MFC Second Edition Microsoft Press Jeff Prosise
 Programming VISUAL C++ 6.0. Fifth Edition Microsoft Press David J. Kruglinski
 Programming Windows with Microsoft VISUAL C++ 6.0. Steven Holzner Distilled
UML booch, rombough, Jacobson.
 Software Engineering by PRESSMAN
 PIS Software Requirement Specification
Websites
 www.MicroSoft.com/
 http://msdn.Microsoft.com/Vstudio/
 www.mindcracker.com
 www.Codeguru.com

Port Map
 Port 1L 8-bit output port.
 Port 1U 8-bit output port.
 Port 2 16-bit output port.
 Port 3 16-bit input port.
 An extra port which indicates data direction
(Data direction port)

Hexadecimal equivalent of Control word

Algorithm to Scan Analog Inputs
 Port Configuration.
 I/O Bus enable.
 select slot address.
 set RADEN
 Read slot address
 Check Slot
 Check board type
 Select channel address.
 Set CHAEN
 Set STC* .
 Set RADEN
 Read status from Read Port.(for Checking EOC)
 Set REDEN.
 Read Data form Read port

Algorithm to Scan Digital Inputs
 Port configuration.
 I/O Bus enable.
 Slot address.
 set RADEN
 Check Slot
 IOA0=0.
 Enable RDEN* signal.
 Read data of the first 16 channels..
 IOA0=1.
 Enable RDEN* signal
 Read data of the second 16 channels.

Algorithm to Write Digital Outputs
 The steps involved are:
 Port configuration.
 I/O Bus enable.
 Write slot address..
 set RADEN
 Check Slot
 WDEN* signal.
 IOA0=0.
 Write data on the first 16 channels..
 IOA0=1.
 Write data on the second 16 channels.

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