Transcript UPAC™ Basic Overview presentation

UPAC™ Combustion Control
Features and Capabilities
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Company Background
Present Organization
 Corporate Headquarters & Manufacturing:
Cleveland, Ohio.
 Air Switch Sales, Order Processing, Customer
Service: Cleveland, Ohio.
 Process Sales:
Boynton Beach, Florida, & Cleveland, Ohio.
 Engineering & Development:
Cleveland, Ohio.
 Combustion Product & Systems Sales:
Boynton Beach, Florida.
 Sales/Service Representatives:
111 offices in the USA, Canada, and Mexico.
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Company Background

Hays Corporation was founded in 1901 by Mr. Joseph
Hays. Republic Corporation joined in 1972. Thereafter, the
company was known as Hays Republic Corporation.
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Cleveland Fuel Equipment Company was founded in 1942
by Mr. Norman Hahn. During the 1950's, the company
moved to it's present location at 1111 Brookpark Road, and
its name was changed to Cleveland Controls in 1958.
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Cleveland Controls & Hays Republic consolidated under
Optimum Controls in 1984.
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The two corporations sold assets to UniControl Inc. during
1994.
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The combustion control product lines of the Hays Republic
division and the Cleveland Controls division were further
consolidated as Hays Cleveland during October 1996. The
air switch product line remained as Cleveland Controls.
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Company Background &
Significant Achievements
 Hays Cleveland is a pioneer developer of in-situ
flue gas O2 analyzers, parallel positioning and
metering systems, O2 trim systems, crosslimiting and deviation limiting strategies, and
SCADA workstations.
 Industries Served: Combustion Products
 Fire tube and Water tube Boiler Applications
 Federal & State Institutions.
 Utilities: analyzers, recorders, indicator.
 Process: mechanical, automotive, all private
industry.
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Combustion Control Product Lines
• Controller Lines:
 UPAC™ Universal Programmable
Automation Controller
 DirectLink™
 Dedicated purpose:
• C-07720 Draft Control System.
• C-07200 Manual/Auto Station.
• R-09500 Draft Regulator (“CDR”)
 Single-loop controllers.
 Multiple loop controllers
(C-07000AC Station Series).
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UPAC™ - Introduction
The new Hays Cleveland UPAC™ package provides complete
facility control, monitoring and communications with the accuracy,
speed and advanced capabilities expected in high-end PLC and
PC automation products--at a much lower than expected
investment! With UPAC™, boiler plant operations and other facility
operations are fully integrated in one platform. UPAC™'s modular
approach provides almost unlimited capability. Components
include a touch screen, control unit and modules for analog and
digital I/O.
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System Overview: Hardware
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Features
PLC
Upac™
Dedicated Analog
Measurement & Control
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Yes
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Optional
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Optional
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Custom and Complex
example algorithms
Control Algorithms:
Advanced PID
Floating Point
processor
Complete Programming
tool
Ethernet & Web
Connectivity
Digital Logic
Real-time OS
Industrial Temperature
Range
Shock & Vibration
Resistant
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UPAC™ Controller CPU
P/N 42026
Multi-function platform
Modular & open architecture, both for
industrial applications and for process
system automation units.
Maximum connectivity guaranteed by
various interface ports: RS-232, 485,
Ethernet, & Fieldbus
Add Analog, Digital & RTD Modules
to configure system.
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System Overview: Hardware
UPAC™ Controller CPU Specifications
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ARM 32 bit processor
4 Mb flash memory, 16 Mb RAM
16Mbyte DRAM
128Kbyte SRAM with Battery Backup
1 CANopen master port
1 RS232 service port
1 Ethernet 10Mb programming and supervision port
(Modbus TCP, OPC server)
Optional Port configurations:
• 1 RS485 port (Modbus RTU protocol, Master or Slave
conf.)
• 1 RS232 port (with Modbus RTU protocol, Master or
Slave conf.)
• 1 Profibus DP port (Slave)
• 1 CANopen port (Slave)
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System Overview : Hardware
UPAC™ I/O Modules
• Used With UPAC ™ CPU
for System Applications
• 8-Channel Analog Input
• P/N 42008
• 8-Channel Analog Output
• P/N 42014
• 16 Channel Digital Input
• P/N 42012
• 16 Channel Digital Output
• P/N 42016
• 4 Channel RTD or T/C input
• P/N 42010
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UPAC ™ Mini Controller
P/N 42062
Combines CPU with Analog & Digital I/O
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CPU
• 32bit processor, ARM architecture
• 4mb Flash (2mb for programs)
• 16mb RAM, 64kb for retentive redundant variable
memory.
On-board I/O
• 8 Analog Inputs
• 4 Analog Outputs
• 8 Digital Inputs (24v) w/ counter function (80hz max.)
• 8 Digital Outputs (24v, .5A)
Interface Ports
• RS232/485 Modbus RTU or ASCII
• RS485 Modbus RTU
• Ethernet port with Modbus TCP Server
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Other Mini controller units available
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System Overview : Hardware
UPAC™ Touch Screen HMI
• 12.1” color TFT screen
Standard
• Other sizes available
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800x600 pixel resolution
Cirrus Logic 32-bit processor
600:1 Contrast Ratio
128kb SRAM w/ battery
backup
• NEMA 4 rated.
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Software – OpenPCS
• IEC 61131-3 Programming
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Instruction List
Structured Text
Sequential Function Chart
Function Block diagram
Ladder diagram
• Standard IEC Function library
• Hays Cleveland Custom library
• Online Debugging
• Offline Simulation
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Software – Indusoft Webstudio
HMI software package
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Web interface that allows you to visualize
screens in a Web browser
Platform-independent application
Online, remote application management
and configuration (download/upload,
commands, system and network
diagnostics, and debugging)
Screen and object password-protected
run-time security
Full-featured objects and dynamics with
customizable object properties such as
bar graphs, color, resizing, position,
rotation, hide/unhide, commands,
hyperlinks, and text input/output;
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Connectivity
Ethernet modbus TCP/IP
communications between
HMI, Controller and SCADA
RS232 serial &
RS485 modbus
CanOpen
protocol to
modules
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Connectivity
Plant
Master
Modbus TCP/IP
Communications
Standard Communications to SCADA is through
Modbus TCP/IP. Other solutions such as
gateways can be provided for interfacing with
building management systems such as
LonWorks, BacNet and Metasys
Network
Switch or
Gateway
SCADA or Building
Management
System
Modbus TCP/IP Communications
Boiler 1
Boiler 2
Boiler 3
Boiler 4
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Applications - Combustion
Control
UPAC™ enhances operator awareness,
improving efficiency and safety throughout the
facility. It can control more than 10 devices for
applications ranging from boiler combustion
control to DA tank and condensate tank control.
For example, in a typical parallel positioning
application with O2 trim and boiler efficiency
monitoring, UPAC™ would control the gas and
oil valves; FD damper and FD damper VFD with
by-pass; FGR, feed water control valve, draft
damper and boiler feed water pump VFD.
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Applications
• Single Package Plant Automation & Control
• Linkageless Servomotor Control
• Single Point to Full Metering Combustion
Control
• O2 Trim Control
• Advanced PID Control
• Boiler Lead-Lag Sequencing
• Pump Sequencing
• Feedwater Control
• Surge Tank control
• BMS Interface
• Flow & Efficiency Computations
• Economizer Bypass Control
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Plant Wide Control
Enhanced Plant wide control with the
UPAC™ can include:
•Plant master operations
•DA & Condensate Tank level control
•Feedwater pump sequencing
•Fuel Oil Tank level monitoring
and provide one central location for operator
viewing and control.
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Boiler Combustion Control
A typical parallel positioning application
with O2 trim and boiler efficiency
monitoring, UPAC™ controls the gas and
oil valves; FD damper and FD damper
VFD with by-pass; FGR, feed water
control valve, draft damper and boiler feed
water pump VFD, all while monitoring the
economizer IN and OUT temperatures
and calculating overall boiler efficiency.
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Boiler Control Operations
(cont.)
UPAC™ parallel positioning and
metering applications use the same
Hays Cleveland UL 1998 Certified
Strategies as our AC Station™
hardware platforms. For safety, both
cross-limiting and deviation-limiting
logic as well as actuator failure
detection are employed in these
strategies to prevent the occurrence of
low excess air.
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Control Screen Examples –
Overview screen (
Home button)
The Home button will
display the Boiler
Overview screen
which gives the
operator the current
status of:
•Temperatures
•Flows
•Firing rates
•Flame safeguard
status
•Servo positions
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Control Screen Examples –
LOCAL BOILER MASTER
The Local pressure
master screen is
present on both boiler
controls and allows for
either manual control
from the operator, or
automatic control based
on boiler pressure.
This loop is only active
when “LOCAL
MASTER” is highlighted
below the bargraph.
This is normally due to a
plant master signal
failure.
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Control Screen Examples –
BOILER SUB-MASTER
From the Pop-up control, touching
the “OIL” button brings up the
boiler submaster screen.
This screen gives the operator an
overview of the fuel/air position of
the boiler.
By touching the “Auto/Man” button
on either the “Submaster” or
“Oxygen trim” loop allows the
operator to take manual control of
that particular loop.
The Fuel /Air auto/manual buttons
are disabled while logged in as
operator.
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Control Screen Examples –
FEEDWATER CONTROL
Touching the “FEEDWATER”
button on the pop-up menu will
display the feedwater control
loop.
This screen provides the
operator with the current status
of the:
•Boiler drum level
•Steam flow
•Feedwater flow
•Actuator position
The operator can also take
manual control of the feedwater
by touching the auto/man button
and specifying a valve
percentage.
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Control Screen Examples –
DRAFT CONTROL
Pressing the “DRAFT” button
on the operator pop-up menu
will display the Draft Control
screen. On this screen you
will find
•Draft control setpoint
•Actual/current Draft value
•Draft Actuator Position
•Auto/Manual Status
While logged in as Operator,
you can place the draft control
loop in either auto or manual.
While in manual mode, the
operator can select the
position of draft actuator to be
held at.
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Control Screen Examples –
TREND SCREENS (
)
The “Trend” icon on
the main menu will
bring up a list of
available trends for
display. The format
for each trend screen
is the same, with the
large trend graphic,
ranges to the left
side, and the legend
for each line at the
bottom of the screen.
The check boxes in
the legend area will
turn on or off that
particular line.
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Control Screen Examples –
HISTORICAL ALARMS (
)
The historical alarm
icon will display all the
alarms from the last
seven days that the
UPAC has monitored.
This screen will give
you the date and time
of the alarm as well as
the current status.
The legend at the
bottom of the screen
is the color legend to
help identify the state
of the alarm, whether
it has been
acknowledged (green)
or has returned to
normal (blue). This
color code also
applies to the Alarm
Pop-up display.
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Control Screen Examples –
Plant Master Control loop
The Plant Master Screen
is the main screen that
should be displayed
most of the time. At a
glance, the user can see
the header pressure,
master loading demand
signal to all the boilers,
header steam flow, and
the outside air temp.
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Control Screen Examples –
Feedwater Pump Sequencers
The Feedwater Pump
screen provides the user
with information
regarding the two-pump
sequencer for boiler #4
feedwater, and the three
pump sequencer for
boilers #1,2,& 3. Included
for each set of sequencer
controls are:
•Auto/Manual for each
pump
•Lead pump select
•Lead and lag pumps
cut-in (On) and cut-out
(Off) points.
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Control Screen Examples –
DA Tank Control
There are individual
screens for each DA
Tank. The
corresponding screen
will give the user the
current tank level, tank
water temperature,
and the fill valve
position.
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Control Screen Examples –
Condensate Tank Control
The Condensate tank
screen accessible from
the operator pop-up
menu gives the user an
overview of condensate
system. This consists
of:
• Makeup water flow
• Return water flow
• Transfer pumps and
sequencer status
• Tank level, and
• Fill valve position (If
installed).
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Control Screen Examples –
Fuel Oil Tank Screen
The control system
monitors the status of
each fuel oil storage
tank. The individual
tank levels, high and low
level alarms are
provided from the
Omntec fuel oil
monitoring system and
are displayed on the
Master UPAC control.
Access to this screen is
from the operator popup menu, “FUEL OIL
TANKS” button.
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Engineering Services
We program each UPAC™ system for a
specific application. Typical packages
include the auxiliary instrumentation
necessary for a complete system: level
and pressure transmitters, flow meters
and actuators, and an optional SCADA
workstation. Complete wiring and system
schematics are provided.
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SUMMARY
We greatly appreciate the opportunity to present
this material to you. Please contact the Sales
Department (561-734-9400) or your local Hays
Cleveland Representative for quotations,
specifications and sales support.
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