Development of demonstration units for Siemens SPPA
Contents
1. ur 502 weg IL das 5082 y peep gt FE 66 5 800v dave Pu 9043 aed aged FEF 1 Aen 101212 09922 S10HIMOJ Q3J1 S10HINDJ Q231 5153 1001 X ti m mi 8 87201117 RR E ANI OT dei 3 5 LI amp Od E2. CONNECTIONS TO OTHER PROJECTS NO Tr POR THE 711 1 1 16 e COST EIMITS 9 2 REPORTING ROU PEN INTELLECTUAL PROPERTY 5 SS BASIC INFORMATION PURPOSE The purpose of the project 15 to develop three demonstration applications based on an instrumentation and control system chosen by Vattenfall EXPECTED OUTCOME EXPECTED OUTCOME OF THE PROJECT The project should design implement and test three physical demonstration applications Two of them should be fairly simple and one more complex If the project team will consist of two thesis students they should design one simple application each and the complex together The following steps are to be performed within the project Assignment specification Vattenfall s responsibility Project specification containing o Time plan and budget o Description of the suggested demo applications o Test plan Introduction to the chosen control system Siemens SPPA T3000 Detailed design of demo applications o Functional description o Hardware setup description Construction o Build control system o Build applications Programming o Implementation o
3. zi 1 IS b 4 T EON 2152 gt MATATA EL gt 3 ha 221 2 APPENDIX G RELAYS SCHEMATIC M X1 1C 5 15 1 2 RELAY X 24V 2 1 GND X2 2 3 1 5V RELAY X 2 GND X4 1 C Singnal1 wa FA 5 1 zt At Eup B A X6 1 LC NV2R K1 24V X4 2 Edown X6 2 olgnal2 5 2 APPENDIX H RELAYS CIRCUIT w N 54 AU Aggregat 24 mere oh 3 SNB mae R LI 259 1 APPENDIX I KIT 67 DC SPEED CONTROLLER SUPPLY MOTOR SUPPLY R KIT EXT MOT 0 MOTOR ALWAYS CONNECTS TO MOTE 1 INSERT LK1 IF USING COMMON POWER SUPPLY FOR BOTH MOTOR AND CONTROLLER CONNECT POWER SUPPLY TO REMOVE LK1 IF USING SEPARATE POWER SUPPLIES FOR MOTOR AND CONTROLLER CONNECT CONTROLLER SU PLY TO V CONNECT MOTOR SUPPLY TO E NOTE 2 ADJUST FOR MAXIMUM SPEED SEE DOCS APPENDIX J OPERATION AMPLIFIER CA3140E TOP VIEW ABSOLUTE MAXIMUM RATINGS OFFSET NULL 8 STROBE DC SUPPL
4. 52 0 1 X T Abet ONO APPENDIX B PULSE WIDTH MODULATOR CIRCUIT E TT ISSN 23541 APPENDIX C DISPLAY SCHEMATIC GNDIO EL817 4 5V GNDIO GNDIO GND 5V GND DISPLAY e e CI Q LL APPENDIX D DISPLAY CIRCUIT LIST IB B B _ i mE VX EX CX GX Mb Wb Wb 1 L 1 1 xK APPENDIX COUPLINGS SCHEMATIC R1 LEDs 1 4 1 2 2 3300h LEDs 2 4 24 gt X2 1 3300h 2 LEDs 3 4 GNDIO x32 3300h 1 2 E LEDs 4 4 2 3 X3 1 son LEDs Bottom GNDIO C X4 2 LEDs Tank GNDIO X4 1 24 R5 LEDs Blue X7 1 8 5 2 24 RE LEDs Green X7 2 CO Q X5 1 68 24 E LEDs Red 4 0 40 0 62 6806 24 Operation Valve 2 6 LX 10 2 X10 1 24 Safety Valve C x112 X11 1 C X12 2 Ge X12 1 GND Sensor GND X9 2 QA X14 2 oV Sensor Vs 134 0 0 144 Analog In Sensor Vout 132 15 2 Analog In Vout X15 1 APPENDIX F COUPLINGS CIRCUIT PPP
5. 3 1 3 INCEUDE DEE 3 1 4 REPORT DISPOSITION zi E SOLE 3 2 METHOD esel ese eee 4 Zal ASSIGNMENT SPECIFICATION 4 2 PROJECT SPECIFICATION dos o mise ht 4 2 3 CREATING THE MODELS FROM IDEA TO FINISHED PROTOTYPE 5 3 SIEMENS POWER PLANT AUTOMATION T3000 6 3 1 INTRODUCTION AND OVERVIEW 6 322 FIRST VIEWS ON THE PROGRAM MING s osea 7 3 3 FUNCTION BLOCE 7 3 3 1 Decimal to binary converter Dec2Bin ER ewe Binay GENET AION sid 22 D Em 9 3 3 5 Pseudo Random Number Generator hene en eee nene rennes 9 2400 REG 10 4 POWER _____ _ _ _ __ _ __ _ _ 10 4 1 SEC ATI 10 4 2 XI ME uL Id 11 4 2 1 How to series connect two ATX computer PSUs to be able to supply 24VDC 11 VATTENFALL ILLUSTRATED LIQUID MODEL 14 5 1 SPECIFICATION 3
6. Development of demonstration units for siemens SPPA T3000 Control System Utveckling av demonstrationsenheter till Siemens SPPA 13000 Kontrollsystem Bachelor of Science Thesis in the Bachelor Degree Programme Mechatronics CHRISTIAN GRUFFMAN KRISTINN SIGMUNDSSON Chalmers Supervisor Morgan Osbeck Department of Automatic control Automation and Mechatronics Division of Signals and Systems CHALMERS UNIVERSITY OF TECHNOLOGY Examiner Kjell Brantervik Gothenburg Sweden 2007 12 15 Bachelor of Science Thesis 2007 Development of demonstration units for siemens SPPA T3000 Control System CHRISTIAN GRUFFMAN KRISTINN SIGMUNDSSON Department of Automatic control Automation and Mechatronics Division of Signals and Systems CHALMERS UNIVERSITY OF TECHNOLOGY Gothenburg Sweden 2007 Development of demonstration units for Siemens SPPA T3000 Control System CHRISTIAN GRUFFMAN KRISTINN SIGMUNDSSON CHRISTIAN GRUFFMAN KRISTINN SIGMUNDSSON 2007 Bachelor s Thesis 2007 ISSN Department of Automatic control Automation and Mechatronics Chalmers University of Technology SE 41296 Gothenburg Sweden Telephone 46 0 31 772 1000 Development of demonstration units for Siemens SPPA T3000 Control System CHRISTIAN GRUFFMAN KRISTINN SIGMUNDSSON Division of Signals and Systems Chalmers University of Technology PREFACE The work in this thesis was performed at Vattenfall Research amp Development AB in Alvkarleby Sweden We wo
7. Describes the aforementioned system and programming needed for the models e Power Supply page 10 Describes the development of the power supply unit used in this project Vattenfall Illustrated Liquid Model page 14 Contains specification purpose method and results for the model Vattenfall Environment Model page 25 Contains specification purpose method and results for the model Vattenfall Robotic Arm Simulation page 25 Contains specification purpose method and results for the model e Result page 29 A brief summary of the results as well as recommendations on future work References Page 31 Information sources for this report are presented here 2 METHOD This chapter describes how the models were created from the assignment specification to delivery It is separated into several chapters one for each major part of the development process Detailed construction and design information for each model isn t included here but in each of the models specific chapters 2 ASSIGNMENT SPECIFICATION The project started with an assignment specification received from Vattenfall AB see Appendix L where the major requirements on the demonstration units were that They should represent and visualize an easy understandable process They should be illustrative by using for example lights and or movable parts They should be easy to set up and start Robustness and stability is more import
8. Perspective view of VILM The sheet metal also provided as a good stabilizer for the elevator bought from Linak Scandinavia AB The first water reservoir to be built was too thin so when filled with water the sides became concave It was constructed from 3mm Polymethyl methacrylate PMMA boards that were glued together We decided Figure 5 3 Perspective view of VILM 5 5 that it did not meet our requirements on a robust construction To get a more robust construction it was decided to build another water reservoir also built upon PMMA but with a thickness of 8mm This tank meets our requirement and looked robust enough A drain valve was mounted at the right lower corner of the tank for the use of draining and refilling the water reservoir 17 5 5 1 The Light Emitting Diodes As the finished models are to be displayed to various types of personnel s from Vattenfall an early decision was made to make the models informative as well as fun and flashy As a result of this decision Light Emitting Diodes LEDs are extensively used in VILM There are three sets of diodes in the control tank explained more in chapter 5 6 The Control Tank and there 15 also 16 blue LEDs in the bottom water reservoir The LEDs in the water reservoir blinks a few times at startup and are then constantly light until the model 15 shutdown The diodes 03mm EL 202 were bought Figure 5 4 Diode from Elfa what was of interes
9. thick as our our acrylic plate was 8mm thick theirs was 5mm Because of this the LEDs wouldn t fit as they were supposed to and more silicon was needed to ensure that the tank would be water proof 5 6 1 Pressure Sensor MX2010DP When selecting a pressure sensor the most important specification to look at is the pressure range The pressure range that is ideal for an application is one that is specified for the exact range that the application will work within As this is never the case one that 1s as close as possible with a high degree of sensitivity is mostly chosen A pressure sensor that suited our needs was MX2010DP found at Elfa This model sends an MPX2010GP mV signal which can be worrisome Sensors that CASE 344B transmit with a mA signal are less Figure 5 6 Pressure Sensor MX2010DP 19 electromagnetic and distance sensitive but the price and pressure range suited the projects needs The MX2010DP has a pressure range of 0 10kPa 0 1m water which would be enough the control tank is 0 4m high The sensitivity is approximated 2 5mV kPa which means that the sensor sends a signal between 0 25mV for 0 10 or in our case 0 10mV for 0 4kPa At first we thought this would be a problem considering the rather small voltages and the Siemens systems analog input has the smallest setting of 80mV but test results proved that this was no problem for the control system After changing the supply from our la
10. 21 6 3 2 6 3 3 Windmills The windmills have AC motors 10 20V 50Hz that somehow need to be controlled For the initial approach a simple on off function was designed with a relay on one of the circuit boards that cuts the power supply to a transformer that will supply all three with 10 20 To control the speed of the windmills we recommend that a frequency controller is obtained that 15 controlled with a signal from an analog output in SPPA T3000 Biomass fossil fuel power plant This power generating facility has a train running on a track from the power plant into the mountain and back again The train 15 controlled by a signal from the control system through an optoelectronic coupler A switch is also installed in the mountain that tells the system when the train 15 there The power plant itself is mounted upon a hole under which a water tank with a smoke generator is mounted A fan regular PC case fan will run for a few seconds to blow the smoke up from the cooling tower when the production of the plant reaches a certain limit This hasn t been programmed other than the production limit or coupled in this project 6 3 4 Programming 7 Tel The toughest part of the programming for VEM was to be able to generate random numbers As there wasn t one available in SPPA T3000 a Pseudo Random Number Generator PRNG was developed see 3 3 5 Pseudo Random Number Generator Being vital for the function of t
11. different demonstration units and start gathering necessary information on how to realize them e Design phase By the end of September we will began to construct the first model At the middle of November we will start to create user manuals for the models APPENDIX N MILESTONE PLAN Milestone tollgate 177 _ Mmmm 9 Table N 0 2 Rough time schedule e Discovery Phase Come up with three physically models for Siemens SPPA T3000 System e Pre Study Our pre study will involve Construction ideas choice of material Function description of models Project specification APPENDIX O BUDGET Project budget The project has a budget limit of 25 000 SEK for hardware and material The control system Siemens SPPA T3000 and software licences are not included in this sum but is provided It also has a budget of 20 000 SEK for workshop labour The table below shows the project budget given in kSEK Man cost Travel Material V RAS optional DENN Table O 0 3 Rough time schedule APPENDIX P PROGRAMMING OVERVIEW is ap 5 ge os Duc quo M up 3 2 3 lana LI LI AM DLL 005 I 445 245 295 iade jeuuau 16 1 5195
12. effective controller so a pulse width modulator PWM was bought 5 4 THE CUBOID The cuboids frame is made up by alumina profiles Profile 6 bought from Aluflex AB and its sides are covered by acrylic glass bought from Akriform Plast AB with a thickness of 2mm The alumina profile dimensions was 30x30mm with a variety in height the cuboid itself is 1060x560x560mm At the bottom of the cuboid there are a wooden plate 525x525x10mm to provide as a stabilizer when mounting the sheet metal stabilizer and the elevator and also as a mounting sheet for the diodes belonging to the water reservoir explained more in 5 5 1 Light Emitting Diodes 5 4 1 LCD Display and buttons To get some feedback from the process in the model a LCD display was bought from Fractronics As documentations from LCD displays varies a lot it was important to get one that had a HD44780 compatible control circuit As these are a homebrew de facto standard and a lot of documentation 1s available on these see for instance 8 and 9 It was decided that it ought to be controlled solely by SPPA T3000 and given that the update rate on the system 15 100ms it was known that the presentation of the set value would be a lot slower than with a microcontroller It should be mentioned here that SPPA T3000 is not intended to control a LCD display and similar components but rather large systems where an update rate of 100ms is more than enough A separate connection c
13. first thing that needs to be done when using a computer PSU for anything other than powering up a computer is to make sure it starts directly when powered This is done by connecting the only green wire there is from pin 16 Power on PS ON with the ground from the PSU this according to an ATXI2V 2 0 and 13 Figure 4 2 ATX12V 2 0 standard molex connector 3 and 4 for other PSU Connector standards refer to 5 and 6 Name Color Pin Name Color Shen Orange 13 Orange 3 3V Orange 14 12V Blue COM Black 15 COM Black IN Red 16 PS ON Green COM Black 17 COM Black 2 Red 18 COM Black COM Black 19 COM Black PWR OK Gray 20 5V White 5 5 Purple 21 TSV Red 12V Yellow 22 Red 12 Yellow 23 TIM Red 3 3V Orange 24 COM Black Table 4 2 Pin layout according to ATXI2V 2 0 standard It was decided that both PSUs should be power by one 230V AC so the power was wired from one PSU to the other see Figure 4 3 11 Figure How to connect two computer PSUs to get 24VDC Furthermore the second PSU needed its neutral heightened to 12VDC so 12VDC was connected from the first PSU to the neutral on the second one see Figure 4 4 Two series connected PSUs L 25 1 IB a A oe cC Figure 4 4 Two series connected PSUs The important thing to consider here 1s that the PSU that has its ground potential heightened must not have its ground con
14. landscape with a hydropower plant model in it The power plant will be made of fiberglass with a servo controlled hatch and an emergency release hatch that will only be automatically controlled by the level of the dam Wind power A random generator will control wind speed and the changes are illustrated by increasing decreasing the speed of the wind turbines Biomass coal power plant The Power plant will have a train stopping beside it to drop off biomass coal and then returning to the mountain to pick up more fuel The plant will then start producing power and smoke will come through the chimney The amount of power generated by the plant is regulated by the stop frequency of the train randomly generated Solar power The amount of power generated by the solar panels is regulated manually by using a desktop lamp to illustrate more less sun Changes in power generation will only be illustrated in the HMI 25 When VEM is set to manual mode hydro wind and power plant will be controlled by either the HMI or the control panel History of the power production for each energy source is to be saved and will be viewable in the HMI 6 2 PURPOSE The purpose of VEM was to be an interactive landscape model where the main function was to show trends in HMI 6 3 METHOD The construction work of VEM started with deciding upon dimensions and construction materials The dimensions of the model was decided to be approximately 2m x 1
15. potentiometer Testing of the new PWM control circuit showed that the theories had been correct The OP amplifies the 0 10V analog signal from the control system to an input of 0 15V into the PWM circuit that controls the speed of the pump from 0 100 The PWM signal was analyzed with an oscilloscope to ensure that the output was indeed correct and that 100 were achieved 5 71 How the Operation Amplifier was dimensioned In addition to knowing that the signal from the control system needed to be amplified 1 5 times it was also noted when measuring the output from the analog module in the Siemens system that the analog output is split between A and A Instead of A being 10V at full output and A OV it was actually 6 5 V and 3 5V This and possible potential differences between the electric systems made us use the OP 1 a differential amplifier circuit instead see Figure 5 8 A differential operational amplifier circuit of a simpler non inverted circuit 27 The formula for dimensioning the resistances in the op circuit 1s 11 Uour p Ue Ur b Equation 5 7 And because we want 15V out when the signal in 1s 10V this gives us Ra Ra 15 10 2 5 1 5 R R Equation 5 8 So if we for instance choose 3kOhm and Rb 2kOhm the output will be 1 5 Connection A to Ug and A to Ug complete the circuit and now we ve also solved possible potential problems See the highlighted area i
16. solving 3 SIEMENS POWER PLANT AUTOMATION T3000 3 1 INTRODUCTION AND OVERVIEW The Siemens Power Plant Automation T3000 SPPA T3000 Control System consists instead of like a traditional Distributed Control System DCS of a 1 single server for handling all parts needed to control power plant diagnostics alarms engineering etc This 15 then controlled by one software platform called Embedded Component Service ECS connecting all the parts and feeding them information from a single source so no need for synchronization and the operator can access all the information he needs on one platform SPPA T3000 is right now the latest Figure 3 1 Embedded Component Services technology from Siemens within power plant instrumentations and controls SPPA T3000 15 Java based and everything can be controlled either via web browser or a stand alone Java application With an integrated web server the system can be easily controlled from distance and it is easy to integrate in already existing IT infrastructure This of course puts a huge demand on high IT security The HMI has the ability to be customized different styles and views for different users gives the system flexibility As mentioned earlier everything is integrated in ECS so while you have a HMI like in traditional DCSs you can also access all function blocks FB diagnostics and even force ports to sp
17. 008 http en wikipedia org wiki Pictogram 3 ATX ATX12V 24 pin power supply connector pinout Pinouts ru Online 09 15 2006 Cited 04 23 2008 http pinouts ru Power atx v2 pinout shtml 4 Intel Corporation Formfactor org Formfactor org Online 03 01 2005 Cited 04 23 2008 http www formfactors org developer specs ATX12V PSDG 2 2 public br2 pdf 5 Formfactors org Formfactors org Online Intel Corporation Cited 04 23 2008 http www formfactors org 6 Pinouts ru ATX BTX WTX and other power supply cables connectors pinouts listing Pinouts ru Pinouts ru Online Cited 04 23 2008 http pinouts ru pin Power shtml 7 Elektronikforumet Online 2008 Cited 12 17 2007 http elektronikforumet com forum viewtopic php t 2 1030 amp postdays 0 amp postorder asc amp start 15 8 Elektronikforumet Elektronik Wikin HD44780 ElektronikWikin Online Cited 05 13 2008 http www elektronikforumet com wiki index php title HD44780 9 Ouwehand Peter Peer s Corner How to control a HD44760 based character LCD Online 06 15 2006 05 13 2005 http home iae nl users pouweha lcd lcd shtml 10 Cengel Y A Turner R H Fundamentals of Thermal Fluid Sciences 2nd ed 2005 ISBN 0072 45426 1 11 Lindahl P E Sandqvist Margivare M tning av mekaniska storheter och temperatur Lund Studentlitteratur 1996 ISBN 9144 00054 5 12 Seattle Robotics So
18. 5m this because there was a need to use buildings and wind power stations used when building model train landscapes For the model to be sturdy relatively easy to move around and still waterproof for the river and dam glass fiber was the chosen construction material for the landscape The foundation of the electrical solutions was laid with the development of VILM almost no electrical solutions needed to be redesigned For regulating the water level in the dam the same circuit board design as was used to regulate the control tank level in VILM except it was be programmed differently in SPPA T3000 The only thing that was needed was a circuit board for some relays and wiring 6 3 1 Landscape construction As mentioned earlier the landscape was to be constructed with glass fiber To do this a foundation for the model needed to be made in another material to build the glass fiber upon Scourging the internet and looking within Vattenfall for solutions several methods were Figure 6 2 Basic foundation found mainly to build the base with e Sand and concrete as Vattenfall does today with its larger models e Modeling with joint foam e Making rough wooden model 26 e Making the foundation with different types of Polystyrene Frigolit Styrofoam etc The choice was pretty easy considering time limits and budget building a foundation with the Polystyrene Styrofoam was considered the best option Bi
19. UTINES Initially the project performers should write a project specification defining the task which will be agreed upon with both Chalmers and Vattenfall The project will be progress reported in short written form to Vattenfall supervisors every second week In the final phase of the project the work will be concluded in a final report to Vattenfall and a thesis report It is up to the project team to decide whether to do two separate reports or not INTELLECTUAL PROPERTY RIGHTS Since the report of this project is a thesis the access to it will be open Any findings from the project not published in the report will belong to Vattenfall AB Group Function Strategies SECURITY The research programme VISP which this project will be performed within is a Vattenfall internal project and should not be communicated outside the Vattenfall Group Therefore the performers of this project will work under secrecy agreements However every result of this project should be formulated in such a way that it could be published outside Vattenfall and thus should exclude detailed information about VISP APPENDIX L Page 2 APPENDIX M TIME SCHEDULE Phase of Project 1 111117 Design and Implementation VILM Design and Implementation VEM Design and Implementation V RAS optional ucc HE Final Report Table M 0 1 Rough time schedule Discover phase By the middle of September we will have come up with three
20. Y VOLTAGE BETWEEN V AND V TERMINALS DIFFERENTIAL MODE INPUT VOLTAGE NON INV E OFFSET INPUT V 8V NULL INPUT TERMINAL OUTPUT SHORT CIRCUIT DURATION NOTE 2 ud enes vera INDEFINITE OPERATING CONDITIONS TEMPERATURE RANGE 55 C TO 125 V SUPPLY 15V TA 25 C APPENDIX K PRESSURE SENSOR MPX2010 MPXV2010G SERIES MAXIMUM RATINGS NOTE NOTE Exposure beyond the specified limits may cause permanent damage or degradation to the device OPERATING CHARACTERISTICS Vs 10 25 C unless otherwise noted P1 gt P2 Vs 4 THIN FILM TEMPERATURE LC V SENSING em COMPENSATION dad ELEMENT AND LL CALIBRATION Vout CIRCUITRY L MPX2010GP CASE 344B PIN NUMBER PINNUMBER 1 66 3 ve 2 Nor APPENDIX L ASSIGNMENT SPECIFICATION ASSIGNMENT SPECIFICATION VISP I amp C POCKET DEMO Enclosures Abstract TABLE OF CONTENTS BASIC INFORMSA TION oases Sa M H EXPECTED OUTCOME EXPECTED OUTCOME OF THE PROUEC T
21. a demonstrationsutrustningar designade och utvecklade utav oss och med hj lp av SPPA T3000 s egna utvecklingsverktyg konstruera ett M nniska Maskin Interface HMI for dessa modeller Den f rsta modellen som byggdes kallas for Vattenfall Illustrativ Liquid Model och illustrerar enkel kontrollprocess for reglering av h jdniv n av vatten 1 en beh llare Den andra modellen kallad Vattenfall Environment Model illustrerar nagra av Vattenfall AB s huvudsakliga energik llor i drift sa som Vind Vatten och kolkraft Bada modellerna kopplas till SPPA T3000 systemet och kontrolleras samt illustreras med hj lp av dess HMI system Resultatet av examensarbetet har blivit en fullt funktionell demonstrationsutrustning som illustrerar SPPA T3000 funktionalitet p ett enkelt och lattforstaeligt s tt Den andra modellen ar komplett 1 beskrivning programmering och visuellt monterad men saknar underliggande komponenter f r styrning Rapporten ar skriven pa Engelska Nyckelord Mekatronik Vattenfall Siemens Power Plant Automation T3000 SPPA T3000 TABLE OF CONTENTS NOMENCEA 56 1 1 INTRODUCTION AND 3 1 1 PORPOS E ee Cee Rte ee en TE EO 3 1 2 BACKGROUND E d M EI
22. ant than complexity e The applications should demonstrate some of the control systems feature such as alarm handling trending etc At least one of the applications should be interactive and able to be controlled by a user without any knowledge of the system e They should be realized with a total budget of 25 000SEK for materials and 20 0008EK for manufacturing workshop working hours 2 2 PROJECT SPECIFICATION After the assignment specification had been thoroughly reviewed and both parts agreed on what was vital for the project and what wasn t several ideas started to take shape After revising the assignment specification and sorted out ideas that wouldn t fit three remained and was named e Vattenfall Illustrative Liquid Model VILM e Vattenfall Environment Model VEM e Vattenfall Robotic Arm Simulation VRAS It was decided that the models would be developed in the order as presented above with V RAS as an optional unit should there be enough time to realize it Time schedule milestone plan and project budget was setup see Appendix M These along with the rough specifications of the models was written in a Project Specification and given to Vattenfall for verification 2 3 CREATING THE MODELS FROM IDEA TO FINISHED PROTOTYPE After the project specification a general idea for the different models had already been put down on paper Before development of the models could start detailed specificati
23. b PSU where it was tested with 10 0V to our modified PSUs 10 3V to our modified computer PSUs the control system didn t receive a signal from the pressure sensor debugging with a multimeter showed that there was a signal seemingly correct sent from it After some experimentation the supply was changed from an intended 10 3V to 5V this gave us a smaller signal in to the control system but with some compensating in the programming for the changes we got correct values again with no noticeable effects on accuracy or sensitivity 5 7 THE PUMP AND PULSE WIDTH MODULATION CIRCUIT The pump by its specifications should be able to handle 4500 liters per hour and be running on 12V This should have been fairly enough when reviewing our calculations Our minimum requirement was that the pump should be able to keep the tank filled with one valve completely opened That is the volume flow rate in 1 25 l s should be at least as large as the volume flow rate out So we calculated the volume flow rate out in optimal conditions assuming that e The flow exiting the tank is steady incompressible and irrotational e The water drains slowly enough that the flow can be approximated as steady or quasi steady as the tank begins to drain Water runs freely through the hoses and there for 7 can be set at the outlet of the control tank Figure 5 7 VILM sketch 20 Start by using Bernoulli equat
24. ciety Whats a servo A quick tutorial Seattle Robotics Society Online Cited 04 30 2008 http www seattlerobotics org guide servos html 13 Wikipedia org Servomechanism Wikipedia the free encyclopedia Wikipedia org Online Cited 04 30 2008 http en wikipedia org wiki Servomotor 14 Park S Miller Random number generators good ones are hard to find Communications of the ACM 1988 Vol 31 10 Pages 1192 1201 3l 32 APPENDIX TABLE OF CONTENTS APPENDIX PULSE WIDTH MODULATOR SCHEMATIC APPENDIX B PULSE WIDTH MODULATOR CIRCUIT APPENDIX C DISPLAY SCHEMATIC APPENDIX D DISPLAY CIRCUIT APPENDIX E COUPLINGS SCHEMATIC APPENDIX F COUPLINGS CIRCUIT APPENDIX G RELAYS SCHEMATIC APPENDIX H RELAYS CIRCUIT APPENDIX I KIT 67 DC SPEED CONTROLLER APPENDIX J OPERATION AMPLIFIER APPENDIX K PRESSURE SENSOR APPENDIX L ASSIGNMENT SPECIFICATION APPENDIX M TIME SCHEDULE APPENDIX N MILESTONE PLAN APPENDIX O BUDGET APPENDIX P PROGRAMMING OVERVIEWS 2 33k 25441 143538 COlMI CLNOO GND GND APPENDIX A PULSE WIDTH MODULATOR SCHEMATIC R3 0 lt O 221931 gt 13538 LLNOO GND ena al 100uF 25V Z GND 92 O s 50 Ak gt 4 F 1N4b04 lt X1 1 0 95 lt c x1 2 2 X2 1 a X2 2 m X3 1 m
25. combining these see Table 4 1 Different output voltages from two series connected PSU s using only 3 3 5 and 12VDC GND 3 3 5 12 15 3 24 GND 3 3 5 12 15 3 24 3 3 s 8 7 12 20 7 5 7 10 3 19 12 5 3 3 12 15 3 8 7 24 1 Table 4 1 Different output voltages from two series connected PSU s using only 3 3 5 and 12VDC 1 3 3V from PSU2 2 12V from PSU2 10 4 2 METHOD We started out by deciding that whatever PSU we chose it should be able to supply all our models with the power they need The requirements were that the PSU should be able to supply voltages of 5 12 15 and 24VDC with currents of up to 10A 24VDC Taking the requirements into consideration when brainstorming for ideas to the power supply we were ultimately left with two choices e Putting together several PSUs for each of the voltages needed To use two computer PSUs and series connect them Considering the economical factor and the amount of current each of these need to supply we decided upon using the series connected computer PSUs The use of two PSUs in a series connection is not because of the added power it can supply but because the highest output voltage from them are 12VDC and this project needs 24VDC for several components Series connecting two PSUS solves this problem 4 2 1 How to series connect two ATX computer PSUs to be able to supply 24VDC Pin 522 3 EWN The
26. des decimal output 3 3 4 Modulo The result of a modulo operation 96 is the remainder of a division Modulo For instance 13 mod 7 or 13 7 is 6 7 goes one time into 13 and 6 is 0 09 OUT the remainder The function takes two inputs INI and IN2 13 and 7 0 09 12 in the example above and outputs the remainder This was done by making a regular division removing the integers and multiplying the Figure 3 6 Modulo decimals by the denominator For instance with 273 and IN2 103 the following 1s performed 2 65048 103 Using the Floor FB described above only the decimals are used and multiplied with 103 IN2 0 65048 103 67 This gives 273 mod 103 67 3 3 5 Pseudo Random Number Generator This block was implemented utilizing Park and Millers Minimal standard Pseudo Random Number Generator PRNG 3 The math behind it 15 the following a 16807 m 2147483647 27 1 seed 1 initial seed seed a seed mod m The seed variable is used as the random number and is then sent back to make a new random number The value of a is chosen because it is thoroughly tested and is proven to be pseudo random and generates numbers with full periodicity with the chosen m that is beginning at the initial seed it will loop through every number between 0 2147483647 before returning to the original seed As you can see the PRNG is dependent of the op
27. e two ordinary stainless pressure buttons ordered from Conrad their purpose is solely to change the set value manually without the HMI They are directly connected to the digital in port at the Siemens PLC and they are programmed to be able to change the value by holding them down a longer time period For instance a quick push changes the value by 1 point up or down but holding a button down for five seconds changes the value about 50 points 16 5 5 WATER RESERVOIR AND VALVES We wanted the water reservoir to cover the whole bottom of the tank excluding a space in the middle for the mounting of the elevator see Figure 5 2 Water reservoir with sheet metal and valves the plate seen at the bottom around the middle of sheet metals is actually the bottom of acrylic glass and not sheet metal This made mounting the valves into a bit of a problem because they are over one kilogram each A way to mount the valves in the model needed to Figure 5 2 Water reservoir with sheet metal and valves found and our solution was to design a sheet metal stabilizer hereafter referred to as the sheet metal To be able to fasten the sheet metal properly it was formed to cover the bottom of model under the elevator Furthermore it was bent and shaped to cover one side on top of the reservoir and then bent up to follow the front side of the cuboid allow for mounting the manual valve to have its handle outside the box see Figure 5 3
28. ecific values See Figure 3 2 below for System difference between traditional DCS and SPPA T3000 Classic DCS SPPA T3000 Thin 1 Thin Clients 8 Operator Terminals 455 a Historian server nostics modules B il d 2 EL ds Parts cU Ns UT Figure 3 2 System difference between traditional DCS and SPPA T3000 3 2 FIRST VIEWS ON THE PROGRAMMING The first thing you notice when programming with Siemens SPPA T3000 is that it s made to control advanced processes For instance FBs for controlling engines with feedbacks and operating times 15 already built in along with more advanced math for temperature compensating flow calculations etc This project however is not an advanced control process but a rather simple one with some sequence programming So the simple programming needed for the project got a little more complicated as several functions needed to control these processes was missing 3 3 FUNCTION BLOCKS The main function blocks that were needed and programmed for this project was Decimal to binary converter 8 1L e Binary Pulse Generator 9 Floor Modulo e Pseudo Random Number Generator 9 Pseudo Random Number Generator With Intervals The rest of this chapter is dedicated not to specific functions used to program these FBs but to the logic behind each FB 3 3 1 Decimal to binary convert
29. emens Power Plant Automation T3000 control system SPPA T3000 in a logical way with both physical demonstration units of our choice and the built in software system 1 2 BACKGROUND There are no physical demonstration units programs to illustrate Siemens SPPA T3000 functionality in an easy and understandable way The only way to demonstrate it today is in a complex virtual environment Vattenfall AB needs a better way of demonstrating the control system This project will therefore develop at least two out of three demonstration units that in an easy and understandable way demonstrate Siemens SPPA T3000 functionality The built in software will be used to control program and monitor the models 1 3 INCLUDED EXCLUDED Extended technical information about the Siemens SPPA T3000 Control System is excluded from this thesis The economical aspect was taken into consideration when planning the projects but we have not done an extended budget plan Due to time issues the third model Vattenfall Robotic Arm Simulation will not be constructed Extended background information is excluded from the public thesis 1 4 REPORT DISPOSITION e Introduction and Overview page 3 Contains this reports introduction in form of purpose background included excluded and report disposition e Method page 4 Describes how the models were created from the assignment specification delivery e Siemens Power Plant Automation T3000 page 6
30. er Dec2Bin This FB was made by subtracting each of the bits represented dec2bin 4 decimal value checking if the output was larger than 0 and in that case output true on that bit and sending the value to the next subtraction block if not output false and send the previous value to the next subtraction block An example of the workflow when converting decimal 173 to binary is presented in Table 3 1 Figure 3 3 8bit Decimal to binary converter Bit Subtraction Larger or eq to 0 Next Value Resulting bit Bit7 128 173 128 45 45 1 Bit6 64 45 64 19 45 0 Bit5 32 45 32 13 Yes 13 1 Bit4 16 13 16 3 13 0 Bit3 8 13 8 5 Yes 5 1 Bit 4 5 4 1 Yes 1 1 2 1 2 1 1 0 1 1 170 Yes 0 1 Table 3 Workflow when converting decimal 173 to binary Result 173 9 10101101 3 3 2 Binary Pulse Generator The function creates a binary pulse with set length and set pause FLS GEN times It takes three inputs one for run true false and two for on off time float The logic was created by various delay and fixed pulse FBs Figure 3 4 Binary Pulse Generator 3 3 3 Floor Takes float number as input and has two outputs one for integers and one for the decimals The logic behind this is made out of the Dec2Bin converter above but converts the binary back to decimal and outputs the decimals which are a rest product of the conversion separately Figure 3 5 Floor function that inclu
31. eration modulo and to develop a modulo FB a floor function 15 needed So those two FBs has been developed solely for the PRNG although they might come in handy later on Later a and m was changed by experiments with other known primes large although smaller than the ones used in Park amp Millers Minimal Standard to accommodate the fact that Siemens SPPA T3000 only allows 9 significant numbers This has the effect that 2147483647 2147483646 0 because they are both converted to 2 1474834 10 FRMG Interval Figure 3 7 Two PRNGs one with intervals and one without 3 3 6 Sequential Function Chart This was an easy block to make all that was needed was to SFC utilize SPPA T3000 own start stop sequence diagram and link t it so that each time it passes the last block it sends a signal to m o STEF the reset port to restart the sequence 4 POWER SUPPLY Figure 3 1 SFC This chapter describes all about the power supply unit PSU used for the models 4 1 SPECIFICATIONS Our PSU consists of two series connected computer PSUs for the ATX Advanced Technology Extended form factor for newer motherboards 1995 and newer that can deliver 520W each This gives the project a large range of supply voltages for its components even those with large current demands We decided only to use the original 3 3 5 and 12VDC from PSUI along with the original 3 3 and 12VDC from PSU2 but even so lot of voltages are available by
32. f functionality in the SPPA T3000 system Testing Final report Presentation of results in Alvkarleby and Stockholm Some requirements on demonstration applications are They should represent and visualize an easy understandable process They should be illustrative by using for example lights and or movable parts They should be easy to set up and start At least one of the built applications should be portable The applications should use the same I O rack interface to the three demo applications and change between them should be simple e g by using a multi poles connector APPENDIX L Page 1 e Robustness and stability is more important than complexity e The applications should demonstrate some of the control systems features such as alarm handling trending etc e At least one of the applications should be interactive and able to be controlled by a user without any knowledge of the system CONNECTIONS TO OTHER PROJECTS The project will be a part of an internal research programme VISP in Vattenfall TIMING TIME LIMITS FOR THE PROJECT The project will start on 2007 09 03 and finish 15 weeks later 2007 12 10 COST LIMITS COST LIMITS FOR THE PROJECT The project will be given a budget limit of 25 000 SEK for hardware and material The control system Siemens SPPA T3000 and software licences are not included in this sum but is provided Budget for manufacturing workshop working hours is limited to 20 000 SEK REPORTING RO
33. g blocks of Styrofoam were purchased and the model was sketched on almost true scale paper to make sure our buildings and train would fit as originally intended Figure 6 3 Basic foundation with Glass fiber cloth Then the real construction work begun by using a cutting tool often used when constructing model airplanes a large handle with a stretched wire between its ends Electricity is applied to the wire to make it hot and it cuts through the Styrofoam very easily Big blocks were cut according to the sketches and put together to make a very rough landscape see Figure 6 2 Basic foundation When the landscape was done big pieces of glass fiber cloth was cut out in different shapes and fitted onto the foundation see Figure 6 3 Basic foundation with Figure 6 4 Landscape starting to take shape Glass fiber cloth where after polyester was applied followed by more glass fiber and polyester During the process we noted that gradually cutting small pieces of cloth and applying polyester was easier to work with than making larger finished pieces of cloth for the whole model and then working with polyester to mould it After the basic model was finished see Figure 6 4 Landscape starting to take shape two holes for water supply and draining was cut out and 1 hose connectors were firmly attached with glass fiber and polyester Two holes 3 8 were then cut out and pipes were put in the water power station
34. he VEM model this was done as soon as construction of the model started When the PRNG was complete and tested the programming was concentrated on making a sequence that generates and calculates power generation numbers for all the different parameters wind total consumption etc and developing a good looking trend window to display these on What s left to do is to make a simple sequence for the train and smoke fan for the fossil fuel power plant VATTENFALL ROBOTIC ARM SIMULATION SPECIFICATIONS V RAS is a robotic arm with 5 degrees of freedom which will be controlled by Siemens SPPA T3000 and do various tasks for instance pouring up a glass of Cola The complexity of the tasks it will be programmed for will be limited by time and difficulty of controlling it with the system But if time allows it the robotic arm could for instance be in the centre of a machine park or any other sort of illustrative production line 28 8 RESULT 5 1 RESULTS Lot of the time went to brainstorming and gathering information more than the time of building the models Time schedule was carefully but optimistically planned and therefore not fully followed Researching ordering building materials and problem solving was the main parts that were too optimistically planned for and took longer time than expected In the project as a whole trial and error as problem solving was widely used First priority was to create concepts after which the mode
35. ion 10 Equation 5 1 We also know assume that e atm Equation 5 2 V 0 the tank is large relative to the outlet Equation 5 3 2 0 4m and 2 0 0m Equation 5 4 Equation 5 1 to 5 4 gives us 2 z F v 287 2 9 81m s 0 4 2 8m s Equation 5 5 Now all we need is the dimensions of the outlet to calculate maximum volume flow rate We wanted to use 24 dimensions as it s very common parts would be easy to find So 4 19mm which gives us 2 2 42 297 2 27 gt 2 y V 2 8 2 27 6 36e m s 0 641 5 Equation 5 6 Which is definitely less than the pump should be able to supply and this is under optimal conditions and maximum pressure so this should be the maximum flow rate But when consulting with the manufacturer they point out that the 45001 it is supposed to deliver isn t at its maximum pressure height of 4meters but instead at optimal conditions that is pumping horizontally with distilled water When powered with 15 3V instead of 12V the pump got stronger and speeded up the process regulation but it did not meet the original requirements The pumps struggle to keep the water level up proved to be a good enough control process so there was no effort put into adjusting the outlets for less water flow or changing pump It was decided that instead of designing a controller fr
36. ircuit needed to be build because the signals given from the Siemens PLC is 24V and the display circuit can only handle 5V The solution was a circuit 15 with photocouples and resistors at all signal in ports that translates the PLC 24V to 5V signals see Appendix C D The circuit was also fitted with two potentiometers to be able to set the contrast and light strength We started by connecting all the wires from the display through the translation circuit to ten digital outputs and then writing a program that properly initialized it From here on the programming grew organically as more functions were added and in the end a fully functional LCD display controlled solely by SPPA T3000 showed the correct set value on the model There is a lot of room for optimization of this programming by using sequences for displaying the values and using other output modules so called FUM Function Modules the display time could be cut down drastically approximately by 90 One of the main problems when testing the display apart from connecting it right was that it sometimes wrote alien characters The cause of this was that the signal cables where to near the power cables in the electronic box The solution was to first separate the signal from the power cables and to minimize possibility of disturbances the programming was changed to only write the set value when it was changed not continuously as it previously did The buttons ar
37. ls would be constructed Afterwards problems was constantly bumped into it have been hard to plan everything into the smallest detail especially because the models are prototypes The budget for the models was successfully planned for and wasn t exceeded The first model was successfully built and presented there was also a user manual written for this model We got great response from Vattenfall AB for our efforts both on the outcome of the project as on the presentation In the second model there was some work to be done by the workshop of the programming problems that were foreseen for instance working around the problem that there isn t a random number generator in the control system have been successfully overcome There is still some programming left but an estimate of 90 of the programming is finished that includes experiences gathered on problems encountered building the first model Because the lack of time the third model will not be build However it was assembled and tested by connecting it to a computer and using the software that follows it but no effort was put into connecting it to the Siemens SPPA T3000 8 2 OPTIONAL 8 2 1 Continuing the work on VEM A project proposal that includes budget estimates of two ways on completing of VEM both however is exceeding a budget of 100 000 SEK One of them just ensuring the model more as a exhibition object still using SPPA T3000 but not extensively and the other
38. me standing on its short side Inside the box there is a cylindrical tank hereafter referred to as the Control Tank elevator water reservoir pump sheet metal stabilizer two electric valves and one manual valve At the front of the cuboid a Liquid Crystal Diode LCD display will show the set point value in percent At startup the control tank will rise from within the cuboid through the top and lights in the water reservoir and control tank will light up In the Figure 5 1 VILM Finished model centre of the control tank there is an acrylic glass plate with Vattenfall AB s logo milled in it that will light up in green red or blue depending on the system status The level of water can either be controlled through the HMI or with two buttons mounted beside the LCD display on the model In the HMI it s possible to choose between a good and a badly regulated process A safety valve will open if the water gets a few percent above the max level to ensure that the control tank doesn t overflow The manual valve and the electric valve can be used to simulate system disturbances 5 2 PURPOSE In this project the purpose of VILM 1 to be hand on demonstration of the Siemens system involving the audience by letting them change set point values and simulating system disturbances VILM will be an interesting demonstration unit It will mostly show the usage of different HMI controls alarm event handling simple seq
39. n Figure 5 9 Highlighed changes in the original schematics and compare it to the schematic in Appendix I Kit 67 DC Speed Controller to see what changes has been done to the original circuit Ra Rn Rb Uour Uc Ra EO Figure 5 8 A differential operational amplifier circuit 23 113 2 184584 U KIT SUPPLY EXT HDTUR SUPPLY Ra Ra at 9 Lo o ug a Rp 8 15U out Ug Ra GND Figure 5 9 Highlighed changes in the original schematics 5 8 ADDITIONAL ELECTRONICS Apart from the ones mentioned above two more circuit boards were made 5 8 1 Couplings board One board was made just to ensure proper connections between the control cabinet and the model Some resistors were installed on the board for the diodes as well 5 6 2 Relay board This board was made to hold the relays needed for VILM A double relay for the pump and display power supply and a change over switch relay for the elevator to be able to heighten and lower it 24 VATTENFALL ENVIRONMENT MODEL 6 1 Finished landscape 6 1 SPECIFICATIONS This model will consist of a landscape with the four major renewable energy sources hydropower solar power wind power and biomass Turning a switch on a control panel will control these either automatically or manually Hydropower A river is going to flow through the
40. nected to the net as that will cause a short circuit Different voltages using only the 3 3 5 and 12VDC outputs of both PSU s are shown above in Table 4 1 Different output voltages from two series connected PSU s using only 3 3 5 12 and 12VDC It s even possible to get more outputs like for instance 29VDC by using 5 from PSUI and 12VDC from PSU2 In this project we ended up only using 3 3 5 and 12VDC from PSUI along with 3 3 and 12VDC on PSU2 Something to take into consideration is that some computer PSUs might not deliver a stable voltage if the 5V doesn t have a load 7 We didn t experience any problems that could be linked to this statement but we did install a 5W load on each PSU as a pre cautionary measure When constructing our first model VILM we had some problems with one PSU shutting down and found the cause of this to be a very bad dimensioned PID controller Problem was solved with a better PID controller that wouldn t cause as high and frequent current spikes as the old one and with a coil connected between the PWM controller circuit and the pump This limited the spikes that otherwise couldn t be removed without developing a really slow control process 13 5 VATTENFALL ILLUSTRATED LIQUID MODEL 5 1 SPECIFICATION VILM 1s a process control system regulating the water level in a cylindrical tank The system is designed as a cuboid shaped box with acrylic glass on its sides and an aluminum fra
41. om scratch it would be easier and probably more cost and time effective to start with a basic PWM controller kit The kit that was bought see Appendix I was controlled by a potentiometer and the first tests of controlling the pump with that circuit were successful The maximum output signal from the control system is 0 10V and input to the controller needs to be at least 0 12V this because the PWM circuit is powered by 12V 21 However inconclusive test results of the pumps power using different voltages for the controller resulted in the decision that 0 100 output from the control system would represent an input of 0 15V to the PWM controller One should note here that this also guarantees a possible output from the PWM controller of 100 when powering the controller with 12V that 15 you can get an infinite long pulse or infinite small gaps between the pulses This 15 because it isn t dependent on any voltage losses over the control part components anymore and as a result the input control signal will always have an equal or larger potential than the reference base potential 12V here The purchased PWM circuit could reach around 98 effective signal output 5 1 PWM Signal at about 50 monitored with a oscilloscope A new circuit was designed see Appendix A B out of the old one by backward engineering now using an operational amplifier OP see Appendix J instead of the original manual
42. one with more controlling capabilities for instance adjusting wind turbine speeds and water power station throughput 6 2 2 Connecting V RAS to Siemens SPPA T3000 When the V RAS model first was thought out the demands servomotors have on communication speed According to several sources see 12 amp 13 servomotors are controlled using a variable pulse width for instance the de facto standard seems to be that 1 5ms represents the neutral position 90 in a servo that can be positioned between 0 1809 Siemens SPPA T3000 could give us a minimal pulse width of 20ms this 15 on the 29 system this project was working against other setups or future upgrades might change this limitation So it can t be controlled directly by the current Siemens SPPA T3000 setup maybe some kind of bus solution could solve this However a microcontroller that receives positions from the control system communicates with the robot arm and computes the inverse kinematics could be used This would only be interesting if it were to show some kind of HMI from where it could be controlled that or in a machine park where the robot is just a minor part of the control system 30 9 REFERENCES 1 American Society for Quality ASQ Learn about quality 450 Learn about quality Online Cited 04 30 2008 http www asq org glossary t html 2 Wikipedia org Pictogram Wikipedia the free encyclopedia Wikipedia org Online Cited 04 30 2
43. ons of functions design materials and different key components needed to be decided upon The course of action here was Decide upon the key components vital for the models construction such as an elevator for knowing a models required minimum height pump dimensions for minimum size of a reservoir power supply for knowing what currents and voltages can be provided etc Finalize the design of the model and create the drawings necessary for the workshop Choose building materials according to needs such as strength water proof and appearance Start ordering and while waiting for parts look through what needs to be done in the programming Do we need to create our own blocks for certain functions Do we right now see anything that is going to be tough to solve Try to solve it as quickly as possible ourselves or can Siemens help us That s just a few of several questions that need to be answered before the programming should start Assoon as the materials start arriving it s time to begin building the model If needed give the workshop materials and plans e Look into the electronics needed to realize all of the models functions When the model is physically put together and the electronics are done it is pretty much trial and error from here on A problem is found Brainstorm for a solution Test a possible solution Did it solve the problem Finalize the solution Figur 2 1 Schematic view of problem
44. rates a simple control process regulating the level of water in a tank The second model called Vattenfall Environment Model and illustrates some of Vattenfall AB s main power sources as Wind Hydro and Coal Power producing electricity Both physical units are connected to the SPPA T3000 system and is controlled and illustrated with help of the built in HMI system The outcome of the project has been one fully operational demonstration units that illustrate the SPPA T3000 functionality in an easy and understandable way the second model is yet to be assembled by the workshop The report is written in English Keywords Mechatronics Vattenfall Siemens Power Plant Automation T3000 SPPA T3000 SAMMANFATTNING Detta examensarbete ingar 1 f rstudie av VISP gruppen hos Vattenfall AB Examensarbetet har innefattat att realisera ett vergripande projekt inneh llande konstruktion och f rst else av b de mjuk och h rdvara Det fanns inga fysiska demonstrationsenheter eller virtuella program som kunde illustrera funktionaliteten hos Siemens Power Plant Automation T3000 SPPA T3000 mjukvara pa ett enkelt och logiskt s tt Det enda sattet att demonstrera det pa var via en komplex mjukvarubaserad modell Vattenfall AB ville utveckla en demonstrationsutrustning f r att pa ett enklare och logiskt satt kunna demonstrera systemets olika delar och funktionalitet Syftet med detta examensarbete var att utveckla minst tv av tre fysisk
45. s 29 8 21 Continuing the work on 29 6 2 2 Connecting V RAS to Siemens 3000 29 9 REFERENCES C 2 3 31 APPENDIX NOMENCLATURE ABBREVIATIONS DCS Distributed Control System ECS Embedded Component Services FB Function Block HMI Human Machine Interface LCD Liquid Crystal Display LED Light Emitting Diode PID PID Controller Proportional Integral Derivative PMMA Polymethyl Methacrylate PRNG Pseudo Random Number Generator PSU Power Supply Unit PWM Pulse Width Modulation SPPA Siemens Power Plant Automation V RAS Vattenfall Robotic Arm Simulation VEM Vattenfall Environment Model VILM Vattenfall Illustrative Liquid Model EXPLANATIONS Trend A trend is the graphical representation of a variable s tendency over time to increase decrease or remain unchanged 1 When referring to trend in this report trend is a trend picture that is an HMI object displaying the trend of one or more signal values Pictogram pictogram also spelled pictogramme or pictograph is a symbol representing a concept object activity place or event by illustration 2 For instance in SPPA T3000 a pictogram is a symbol for a motor or a valve 1 INTRODUCTION AND OVERVIEW 1 1 PURPOSE The purpose of this project is to demonstrate the functionality of Si
46. t LU a a piante erc 14 5 2 PORTOS 14 359 TREND 14 5 4 110 1 15 541 LCD Display and du to ded ista 72 3 WATER RESERVOIR AND VALVES pp 17 18 5 6 ONT OL LE 19 Pressure Sensor MAZOIODP i cina ut ea t edu tette 19 2 7 THE PUMP AND PULSE WIDTH MODULATION CIRCUIT 20 5 71 How the Operation Amplifier was dimensioned 22 5 8 ON 24 DOS P oO 24 24 VATTENFALL ENVIRONMENT 25 6 1 SPECIFICA ON 22 6 2 PURPOSE NE 26 6 3 METHOD 26 XXVVVV 26 OO 26 6 3 3 Biomass fossil fuel power e e E 28 28 7 VATTENFALL ROBOTIC ARM SIMULATION ee ee e ee ee 28 7 1 SPECIFIC A 28 8 RESULT e PR 29 9 1 ES 29 8 2 has ic ane
47. t for us except color were the specifications of voltage and current We chose diodes with 2 0V and 20mA Using our lab PSU set at 2V to test them and later 6V for a series of three we managed to burn a few of them When connected we didn t take into consideration that each diode series needed its own separate resistance even if connected at the right amount of voltage If connected without resistors the internal resistance of serial connected diodes is too small and causes a current flow which short circuit them 18 5 6 THE CONTROL TANK The control tank was the first feature of VILM that was designed It is cylindrical with an acrylic plate in the middle that has Vattenfall ABs logo milled in it Under this plate in the bottom of the tank Light Emitting Diodes LED in green red and blue are mounted and light up the logo depending on the systems health e Green for correct level e Blue for low level Red for high level In Figure 5 5 Bottom view of the control tank you can see a hole in the top drilled for pressure leveling and the holes in the middle bottom for the LEDs There are also 4 holes for fastening it to the elevator Figure 5 5 Bottom view of control tank and one small hole for the pressure sensor see Appendix K A problem that arose was that the acrylic we bought PMMA wasn t hard enough to mill in so the company that we order the milling from used their own material which wasn t as
48. uence programming and easily constructed pictograms 5 3 METHOD When the development process with VILM began we started by dimensioning the model The model needed to be large enough to easily be seen and understood via a videoconference and yet still be portable Then the search for components began Before 14 ordering and construction could begin an elevator that could lift the cylindrical tank as high as necessary without it being too high itself was crucial otherwise the model would need to be re dimensioned to accommodate for the height of the chosen elevator As the orders for the frame and elevator was sent most of the models components were decided upon and ordered when needed such as pressure sensor valves and hoses In case of small or major changes in the model that would make one or more components unusable in the project everything wasn t ordered at the same time It was decided that the water reservoir would cover the bottom of the model with room for the elevator in the middle Another major dimensioning was made when trying to find the right pump and pump controls for the regulating the water level in the control tank It had to be able to sustain and fill the tank with water within a reasonable time otherwise the process would be too slow we especially looked at how many liters per hour and pressure height the pump could handle When deciding how to control the pump the big issue was to find a cost
49. uld like to take the opportunity to thank all people at Vattenfall AB for an educating and giving time Especially we want to thank our supervisor Mikael Nordlander at Vattenfall Research amp Development AB for valuable guidance and suggestions to our work We are grateful for his involvement of this thesis and the opportunity he has given us We would also like to thank our supervisor Morgan Osbeck and examiner Kjell Brantervik at the division of signal and systems at Chalmers University of Technology for valuable criticism and support ABSTRACT This thesis 19 a part of a larger study under the VISP project within Vattenfall AB The work has been about realizing a comprehensive project that contained both hardware and software There were no physical demonstration units to illustrate Siemens Power Plant Automation T3000 SPPA T3000 control systems functionality in an easy and understandable way The only way to demonstrate it was in a complex virtual environment Vattenfall AB needed to demonstrate the functionality and the different parts of the SPPA T3000 control system in a more understandable way than was available The purpose of this project was therefore to develop at least two out of three physical demonstration units designed by us and use the built in software for development of the Human Machine Interface HMI for the aforementioned control system The first unit we built is called Vattenfall Illustrative Liquid Model and illust
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