Valmet DNA Automation System Description

(TYPICAL – FOR TENDER PURPOSE)

1 PROCESS CONTROL SYSTEM

The TG DDCMIS is based on Valmet DNA (formerly known as Metso DNA) Distributed Control
System.

2 Valmet DNA SYSTEM ARCHITECTURE

The Valmet DNA system architecture is designed to meet the following requirements:

- High system reliability, achieved by using proven system components.

- Flexible usage, achieved by operation functionality in various locations.

2.1 Hierarchy

The Valmet DNA system is built up from different functional units (stations). It has a
decentralized structure and a possibility for later extensions without disturbing existing system
parts. Different sub processes are divided into different stations. Stopping or failure of one
station does not have any influence to other stations.

2.2 Network architecture

The Valmet DNA system network consists of two main networks: the process network and the
Control room network.

The main function of the process network is to connect various DCS stations together to form
an integrated plant control system. Although the process network is based on standard 100
Mbit/s Ethernet, the communication protocol is UDP/IP added with a Valmet DNA specific
application protocol. This network architecture is called switched Ethernet. This way the
deterministic response times on the process network can be guaranteed.

The control room network is a standard 100 Mbit/s Ethernet network with TCP/IP protocol,
defined by IEEE802.3. The control room network ensures that the control room equipment
communicates internally and with the stations connected to the process network. The control
room network is connected (routed) to the process network via managed 100 Mbit/s Ethernet
switches, thereby providing redundancy also.

The internal communication in the Valmet DNA system is name-based. This ensures flexible,
address independent interfaces between applications, within each station and between stations.
The advantage of name-based communication also translates into flexible and user friendly
application engineering. This feature is important to achieve full control integration between
various plant areas. Advanced and continuous diagnostics provide the user with a clear view on
the network and system performance.

System supports both STAR & Ring Topology.

The selection of topology is done purely on the basis of plant layout. Both the topology offers
similar fault tolerance parameters. This can be decided during detailed Engineering stage.
Ring topology is suggested where plant consists of several small subsystems and are
geographically distributed across the plant.

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 STAR topology is suggested where majority of nodes/controllers of sub-systems are located in
centralized location. The offered software and hardware use latest technologies that provide
faster recovery/fault tolerances.

Both the topology can be implemented to have better manageability and maintainability when
the network is designed and integrated into the Valmet DNA system.

2.3 Interface to external systems

Valmet DNA supports various industry standard protocols that can be used to seamlessly
interface with external systems. Typically MODBUS-RS485/TCP, OPC-DA/AE protocols are
used to interface to exchange data seamlessly.

2.4 Expandability

Typically, the following reserve capacities are retained in Valmet DNA system, for turnkey
solutions (as a good engineering practice)

DCS Reserves:
- reserve channels at I/O units: 5 % overall

3 PROCESS STATIONS AND I/O-INTERFACE

3.1 Process Control Stations (ACN)

Process control functions such as measurements, open and closed loop controls, interlocking,
logical functions, calculations, sequences, group control or advanced control functions are
provided by the Process Control Stations (ACN PCS).
Valmet DNA offers ACN (Application Control Node) as Process Control Stations (PCS).

All offered process control stations PCS are redundant and act on a active/hot standby
principle. Take over from the main station to the reserve in case of a fault is automatic and
bumpless.

The key features of ACN are

- High processing power
- Fast control cycles, as low as 20 mS
- One-to-one redundancy capability
- Dual 100 Mbit/s Ethernet connections for communication with other nodes
- Support for multiple field buses
- Standard serial port links for communication with third party devices
- Detachable PMM module containing identification information of the node

3.2 Cabinets

ACN-based stations will be installed in the same cabinets as the I/O modules.
One cabinet includes
- the redundant ACN process control stations
- six (6) I/O groups

The dimension of the cabinet is: width x depth x height [mm] = 750 x 750 x 2125

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3.3 I/O-interface

The connection from the PCS's to the I/O-module groups is Ethernet field bus. The speed of the
Valmet DNA field bus is 100 Mbit/s. The field bus is either twisted pair or fibre optic cable,
depending on the distance and possible EMC requirements.

Each I/O-group includes bus interface and power supply. One IO group contains max. 16 I/O-
units. Various types of I/O-cards can be allocated in one group.

3.4 M120 I/O-units

The M120 I/O-units in Valmet DNA system are multi-channel, but the following maximum per
I/O-card ensures the system reliability to meet the power plant demands:

AII4H 4 analogue inputs (0/4…20 mA), HART, isolation voltage 1500 VAC between
channels
AOI4H 4 analogue outputs (0/4…20 mA or 0…10 V), HART, isolation voltage 1500 VAC
between channels
AOI4C 4 analogue outputs (0/4…20 mA or 0…10 V), isolation voltage 1500 VAC
between channels
DII8P28 8 binary inputs (24 VDC), isolation voltage 1500 VAC between channels
DOI8RO 8 binary outputs (24 VDC), isolation voltage 1500 VAC between channels
TII4W3 4 channel RTD inputs, 3 wire, isolation voltage 1500 VAC between channels
TCI8 8 channel thermocouple inputs, isolation voltage 1500 VAC between channels

The M120 I/O –units are providing a high isolation level that is 1500 VAC between the channels.
ACN I/O is mounted on DIN rail and enables the use of the same I/O in both centralized and
distributed I/O.

Technical features:
- High resolution of AI (16 bits) and AO (14 bits)
- 1 ms time stamping in digital inputs
- Hot swapping of I/O units
- Channel-specific diagnostics
- Fast controls down to 20 ms
- Ethernet connection to ACN controller
- Isolation voltage 1500 VAC between channels
- Software simulation

The more detailed information about the I/O units has been presented in a separate data sheet
in ACN I/O M120 document. The specification of items proposed is subject to changes due to
continuous improvement in the DCS system.

3.5 Functional cycle time

The cycle time is defined as execution time for a specific signal loop. It means the time between
setting an input - calculation - creating an output signal. Following times are normally used:

- 40-5000 ms for normal analog and binary controls

The cycle time of the functions is freely selectable for every loop according to the needs of the
respective functions.

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3.6 Time-stamping

The time-stamping resolution for standard digital inputs is 1 ms throughout the system.

3.7 Power supply

As per offer

4 CONTROL ROOM

4.1 Control room equipment

The operation and monitoring of the process is done by operator stations (OPS's), which are
computers with Windows operating system. Each operator station consists of one flat 22"-TFT-
displays. Operating is done by using a mouse and keyboard. For safety reasons, touch screen
facility is not envisaged.

The user interface is achieved via a number of displays such as:

- Graphic Displays with dynamic operations
- Overview Displays
- Sequence / Step Displays
- Event Displays

Operator stations are connected to the control room network in a redundant manner. From each
operator station, the entire power plant process can be controlled and supervised.

Hardcopies of displays are generated via the color laser printer or B/W alarm laser printer
connected to the network.

4.2 Operators' window to the process

Process control displays can be accessed through every operator station associated power
plant's automation.

DNA Operate is a graphical user interface designed for process control and monitoring.

Correctly performed tasks, early detection of disturbances, and a quick recovery from them form
the basis for a profitable operation. DNA Operate user interface provides the operators with
efficient tools to control large entities and complex situations. The illustrative displays with easy-
to-use analysis tools and quick-to-access support information also form a versatile learning
environment.

The most important components of the DNA Operate desktop are the control panel, Favorites
List, and various picture windows. The control panel includes an overview picture of the process
and a toolbar. With the toolbar function buttons you can perform various general desktop
operations most of which are connected with picture selection.

Process data can be examined through pictures opened on the DNA Operate desktop. The
pictures can contain up-to-date information, history data, plans, and predictions. Pictures are
opened on the desktop in picture windows. There can be several picture windows open on the
desktop simultaneously. Important pictures are easily accessible from the Favorites List and
they can be quickly opened with a single mouse click.

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 The key features of the DNA Operate user interface are:
- Support for total view
o Overview pictures of processes and sub-processes
o Quick and versatile browsing capabilities
- Quick direct access to information and knowledge with easy linking
o Easy-to-learn navigation from the overview picture to more detailed picture
o One-click access to the alarming process graphics
o One-click access to the most frequently used pictures
o Drag-and-drop comparison of trend curves
o Illustrative presentation of history data
o Support information linked to the object
- Adaptability to the tasks
o Efficient windowing
o Modifiable favorite picture collection
- Excellent usability
o Self-guiding
o Only a few rules to memorize
o Consistent principles

4.3 Desktop Structure

Desktop refers to all the windows and their functions displayed on the monitors of a
workstation. A desktop comprises of the following elements:

1 Control panel
Control panel displays an overview picture of an area and its processes. The
overview picture can be changed by clicking one of the area buttons. From the
control panel you can also perform general operations regarding the whole
desktop. In disturbance situations, troubleshooting is started with the alarm
functions located in the control panel. There can be several control panels
simultaneously open on the desktop.
2 Favorites List
The Favorites List contains selection buttons to the most frequently used
pictures. With a single mouse click, you can open the desired picture. You can
easily modify the contents of the Favorites List.
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 3 Picture windows
More detailed data needed for the process control is displayed in the picture
windows and in the tools which can be opened on the desktop. To enable the
efficient use of the desktop in all situations, there are several ways to open a
picture.
4 Working area
The empty area on the DNA Operate desktop is called the working area, which
is designated for picture windows and various tool windows and dialogs. By
default, the control panel is located on the topmost part of the monitor. When a
desktop of two or more monitors is used, windows can be moved from one
monitor to another. You can thus freely arrange the desktop for different
conditions or to meet the needs of different users.
5 Desktop tools
Desktop tools include the trend analysis tool and different maintenance tools. In
the event list, you can view process alarms and their statuses in chronological
order. With drag and drop operations, you can move measurements from the
pictures to the trend analysis tool to view their graphs.

Display types
Following display types are applied as default.
- Process graphic displays
- alarm / event displays
- dedicated trend displays
- sequence step displays
- diagnostic displays

DNAuse

• Desktop
- control panel
Process help
- responsibility areas metsoDNA manuals
- overview picture DNAdiary
Open alarm list
Next and previous alarm page
• Enhanced Acknowledge horn and alarm list
Login
Print desktop
- usability Favorite Window
- information Open DNAuseEditor
New Picture Window
- interaction New Control Panel

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 An example of process graphic display

An example of an Alarm display window and trend display window

Process control
Generally operations are performed with a mouse by pointing and clicking. Numerical
value and text is entered through a keyboard.

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 Loop operations (process controls) are done directly from display window or by opening a
dedicated loop window. Following example (a pump loop) illustrates loop operations.

Control Room Selection (Selecting a Process Area)

The header shows the name of the control room, the data of which the header is
displaying.
The control room of the header window can be changed using the control room
selection option of the header window.

Login
Some operations presume a certain level of user rights. For this purpose the operator
must enter the user name and password to the system. The user name will also
determine the individual desktop properties defined for the specific operator. For
example, the contents of the favourites picture menu may have been defined
specifically for each user.

User authority groups

The users can be divided into three groups with different user authorities. The modes
are as follows:
- Display mode
- Control mode
- Maintenance mode

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4.4 DNAtracer

DNAtracer provides versatile methods to browse and analyze historical data. When DNAtracer
is opened, the trend of the target loop will be automatically displayed. Graphs can be added to
DNAtracer by either drag-and-drop operation directly from a picture window or by using the
History Tag manager. One trend can have up to 10 graphs. With the Replay function, a trend
can be repeatedly updated forward or backward in time, for values selected to data collection.

Trend pictures can be saved for later examination. The trend values can be examined in table
format in a dedicated view. The values of the graphs can be copied to the clipboard for later
use, for example, to be pasted in a spreadsheet.

4.5 Alarm handling

Valmet DNA Operator interface gives the operator overall information about the alarm
situations and facilitates a one-click access to the process picture where the disturbance is
located. In this way, it provides the operator with first-hand information about the incident. 1
mS resolution alarms guarantee accurate and reliable information about what has happened.
Versatile tools for classification and statistical operations support off-line analysis.

acknowledge time inactivation time

The event handling is managed by the Alarm Processor (ALP). The ALP ensures that the
event data is presented to the operator by means of alarm and/or message displays
(integrated part of the operator station display hierarchy), graphic displays, loop windows, etc.
and via a header on the desktop. In addition, the operator is given a number of event
management tools, enabling fast disturbance management. Each event can generate an
acoustic signal.

Event printer driven by the ALP will log all events upon occurrence and clearance, marked
with time stamping.

Time stamping is derived in the following way:

 Digital Inputs; time stamping at I/O card level, 1ms for each input unit.
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  Events derived from analogue values; at loop execution level, minimum is 20 ms.
 Serial data (when time stamps can not be send via data link); at Gateway Station.

Alarm classes:
A certain grouping is configured for all events, in other words, a set of properties is
defined for each event. Based on this grouping the application modules decide whether
to register the event or not.
Each alarm/event is provided with following criteria:
- alarm/process area
o priority
o critical
o normal
- event type
o alarm
o event
o operator tracking event
o mask operation event
- user
o process event
o system event

Alarm displaying:
Alarms and events are displayed:
- in particular alarm/event displays
- in header window
- (loop specific events) in display window where the loop is displayed
- (loop specific events) in loop window
- in alarm/event printer

Alarm acknowledgement;
Alarm sound and displayed alarm (blink) can be acknowledged separately. There is a
special key for acknowledging the alarm sound.
Alarms can be acknowledged in three different ways. These are:
- common acknowledgement
- list acknowledgement
- line acknowledgement
When using the list acknowledgement, the alarm list must be displayed on the monitor.
The line acknowledgement is carried out from the alarm list or from the header. The
common acknowledgement acknowledges all the active alarms on the alarm list. The
list acknowledgement acknowledges all the alarms on the alarm list which are active
and shown on the alarm list page displayed on the monitor. The line acknowledgement
acknowledges an alarm that is indicated by the cursor either on the header or on the
alarm list page displayed on the monitor.
Different types of acknowledgements can be carried out by pressing the right mouse
button and by selecting one of the acknowledgement options from the Function Menu’s
Alarm submenu.

5 REDUNDANCY CONCEPT

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5.1 Operator stations

From each operator station the whole process of SG/ TG/ Station C&I can be handled. The
routing of the control room network is done in a redundant way.

5.2 Process control stations (controllers)

All the process control stations are redundant. In case of failure of main station there is an
automatic switch-over to reserve station without disturbing the process. A system alarm is
generated. Also the power supply of I/O groups is redundant.

5.3 Data back-up

All runtime data, distributed to various stations is stored in the form of database packages in the
Back-up Station (BU). The RAID hard disk of the back-up station contains the configuration of
all stations connected to the process/control room network. From the BU, the application data is
downloaded to each station's runtime environment at station start up. Application modules are
downloaded from the repository of the Engineering Station (EAS) directly to the runtime
environment (smooth on-line facility) and at the same time, a replica copy is added to the
database package, residing in the BU.

After a failure the back-up station will automatically reload the configuration to the respective
station. All actual process information is saved in the back-up station in cyclic intervals.

6 ENGINEERING AND MAINTENANCE

6.1 Engineering

The configuration of the Valmet DNA system is graphical and user oriented. The Engineering
Station (EAS) is based on a PC, running under Windows operating system. The EAS consists of
Engineering Station (EAS), Monitor, Hard drive, CD-ROM, Mouse and AT-keyboard, DLT-drive
for back-up purposes.

The EAS offers a CAD-based engineering environment in which new applications are designed
and existing application can be modified. The CAD-tools offer user friendly configuration
possibilities for the following:
- Control loops and logic functions FbCAD
- Sequences SeqCAD
- Graphic Displays DNA Picture designer

Windows compatible Metso CAD program is used in the engineering system.

FbCAD tool used in EA Server or EA Client workstation and with part of its functions in an
independent Windows XP based workstation (stand-alone workstation).
FbCAD is used in designing function block diagrams, which are control loops related to
controlling and monitoring a process controlled by Valmet DNA . Function block diagrams
consist of configuration functions which include e.g. Process Control Server's (PCS) continuous
controls, I/O functions and mimic panel controls as well as control room's tag, operation and
event functions, and history functions of information management activity.

Function block diagrams together with their configuration functions are saved in the database
located in the EA Server from which they can be viewed with FbCAD or printed. They can be
also opened with Function Explorer to be viewed or modified.
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 A function block diagram created with FbCAD is simultaneously both an application loaded in
the runtime environment and its graphical document. This ensures that the documentation of
the application is even after modifications always up-to-date.

FbCAD provides the engineer with an illustrative and efficient graphic-working environment for
designing Valmet DNA applications.

An example of FbCAD diagram

Function block diagram

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 The EAS’s repository (archive) on its hard disk contains all software application and provides
another level of backup/security to the Back-up Station (BU). The applications, residing on the
EAS, are periodically stored on DLT-tapes. Basic data, gathered during the design phase, is
stored in the engineering database, which forms an integral part of the engineering tools. The
database is used for software generation and documentation purposes during and after the
project phase.

The EAS also includes a feature (UpdateTool) whereby the critical parameter settings can be
updated from the runtime environment directly to the application software in the EAS. This
prevents any settings changed in the runtime environment to be overwritten by a default value.

6.2 Documentation / Language

Documentation results automatically from configuration (self-documentation principle).

Documentation has the same form as engineering loop plan. The length of the tag code is
enough for using any power plant coding system.

By using the UpdateTool it is possible to read all changeable parameters (set points, alarm
limits, controller settings, etc.) from the process control stations back into the repository and the
documentation.

All application documentation (Operator displays, alarm lists) and the operator manuals are in
English language. Application language is always English.

6.3 Configuration changes

The EAS provides an extensive set of archive management commands, which can be used for
revision control. In case of changes of application during process is running it is possible to do it
on-line without disturbing any other part of system or process. For safety reasons old
configuration is stored in a back-up file until new configuration is properly tested. Configuration
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 changes are documented automatically, including new functional loop plan, date and name of
modifier.

6.4 Diagnostics

The DCS offers a full continuous diagnostic routine, checking operations throughout the system,
down to I/O-level. Any defects will be presented to the operator in the form of diagnostic
(system) alarms or messages. The operator will know where a fault has occurred, for example,
wiring faults on 4-20 mA loops will be detected and notification is given to the operator. The
system includes a graphical diagnostic package, which presents the system status, based on
the system structure, specific for this application.

7 INFORMATION MANAGEMENT AND REPORTING

The information database, process performance calculation and reporting functions are carried
out by the Valmet DNA Information Activity (IA).

The information activity is an integrated part of the Valmet DNA. Data between the process
control level and the info system is routed from the process bus to the control room bus. This
allows the name based communication principle to be used also in the info system, avoiding any
intermediate steps. The tag name of data to be stored in the info system data bases can be
defined by means of the unique tag name by the information station user. Plant data is archived
on the hard disk and automatically stored on backup tapes (DAT or DLT).

Info system displays can be viewed from the Operator workstations.

The DNAhistorian, in which the data are stored, forms the basis for the Information Management
Activity. DNA OperaterTools give the ability to handle the stored data and prepare displays,
trends and reports. DNAhistorian database includes role-based security concept, with possibility
to define user rights (read, write, change) per each variable.

7.1 Data Collection and Historians

DNAhistorian is a high-performance data management system for collecting continuous process

data. It is composed of a memory-based database and disk resident historian. The disk resident
history stems from the creation of a state-of-the-art, high-performance process data history
system.

The SQLplus allows system managers to perform SQL queries on the real-time, historical and
configuration data in the DNAhistorian database. SQLplus is a powerful tool for accomplishing
several query and maintenance tasks, providing DNAhistorian with the "look and feel" of a
relational database.
With the DNAhistorian's Data Maintenance Tool the existing values can be viewed and replaced
over a specified time span with either a constant value or with the values of selected database
variable.

DNAalarmHistorian is a database for process alarms and events. It collects and stores all alarm
and event information from different sources into Oracle database. The database is designed
for efficient alarm and event classification based on event types, event sources and priorities.

Capacities:
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 The required disk storage depends on the amount of collectable variables and the storing time.
Typically the database is sized according to the following storing times:

Cycle Type Storing time

1 sec analog 5 days
1 sec binary 5 days
5 sec analog 400 days
5 sec binary 400 days
1 min analog, calculated 1200 days
1 hour analog, averages, runtimes 20 years
day, week analog, manual 20 years

8 ENVIRONMENTAL REQUIREMENTS

These conditions are in accordance with the standard classes of IEC 60721-3-3K2.
The enhanced deviating values for ACN I/O are presented separately. The specification of items
proposed is subject to undergo change due to continuous improvement in the DCS system.

 Operating Temperature +15 ... +30 °C

o ACN CS 0 ... +60 °C
o ACN I/O 0 ... +70 °C
 Max. rate of change : 0.5 °C / min
 Relative humidity: 10 ... 75%, no condensation
o ACN I/O: 5 ... 90%, no condensation
 Absolute humidity: 2 ... 22 g/m3
 ACN I/O: 1 ... 25 g/m3
 Air pressure: 70 ... 106 kPa
 Vibration IEC 60721-3-3M1
o Amplitude 0.3 mm (2 ... 9 Hz)
o Acceleration 1 m/s2 (9 ... 200Hz)
 ACN I/O: IEC 60945
o Amplitude 1.0 mm (2 ... 13 Hz)
o Acceleration 2.0 7 m/s2 (13 ... 100Hz)
 Shocks: IEC 60721-3-3M1
o Acceleration 40 m/s2
o Duration 22 ms, half sine
 ACN I/O:
o acceleration 50 m/s2,
o Duration 11 ms, half sine
 Chemical conditions IEC 60721-3-3C1
 Chemical conditions (G3) ÍSA-71.04 (optional, if required)
 Biological conditions IEC 60721-3-3B1
 Erosion IEC 60721-3-3S1

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Statutory/Regulatory Requirements

The offered equipment shall conform to the Plant Standard ED 049 00 91 Rev. No. 09 of BHEL-
Electronics Division under statutory/regulatory requirements. Apart from this, if any other,
statutory/regulatory requirements are envisaged from the purchaser, the same shall be informed to us
before placing the Purchase Order. Otherwise, our above standard will hold good for the
manufacturing of the equipment.

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