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the manufacture and supply of new generation Distributed Control Systems 'MAX1000+PLUS' , for modern Power Plants & Industries, with MAX Control Systems (MCS) Inc USA, part of METSO Automation.
The MAX1000+PLUS is now re-named as maxDNA. where-in DNA stands for Dynamic Network of Applications. maxDNA is a network of applications where diverse hardware and software solutions co-operate to allow the plant to reach its greatest potential.
BHEL's Electronics Division has established itself in the area of Control & Instrumentation for new power plants as well as renovation and modernisation of existing power plants. A leader in the Indian Power Sector market, it has already supplied and commissioned above 200 sets of DCS for thermal, combined cycle and hydro sets all over the country and overseas.
MCS Inc., USA, former systems division of Leeds and Northrup, USA, is an internationally reputed technology leader In both Power as well as Industrial process control systems, with 70 years of rich experience in the field.
Applications
maxDNA systems are used in many applications throughout the world including electric power generation, co-generation, cement, glass, ceramics, primary metals, chemicals and petroleum, water and waste-water treatment and incineration plants.
BHEL offers a variety of solutions for Power Plants ranging from simple control systems to complex unified automation for Power Plants of any size. The synergy of BHEL's expertise in Power Plant Controls and cutting-edge technology of maxDNA provides for unified DCS solution for entire Power Plant comprising of Steam Generator, Steam Turbine Generator and Balance of Plant C&I. The state-of-the art control system is also configured for complete range of Hydro Turbine governing and auto sequence controls, SCADA systems and for wide range of industrial process applications.
o Steam Generator Controls o Heat Recovery Steam Generator (HRSG) controls o Steam Turbine controls o Industrial Steam Turbine Controls o Balance of plant controls o Data Acquisition and information management o Hydro Turbine Governing and Auto sequence controls o Generator and Switchyard controls o Electrical System controls o Fossil power utility plants o Combined cycle power plants o Captive power plants o Simple cycle power plants o Hydel power plants
Industrial Controls
o Process Industry
The maxDNA allows easy integration of third party devices and communication with external systems. The system also allows user flexibility to operate a small stand-alone control system to a mega control system with plant-wide automation. Its open architecture permits the integration
of process control, management information systems, local and wide area networks, PLC systems and SCADA systems
BHELs integrated Automation and Information Management System maxDNA is a microprocessor based real time system. This system is designed on modular basis, allows scalability and provides operator the complete tool to increase the availability, efficiency and safe operating state with respect to the Process component.
The maxDNA DCS product line provides regulatory control, sequential logic control, operator interaction through CRTs (MAXSTATIONS) and information management. The MAXSTATION can be configured as an operator station, engineer's station, historian (MAXSTORIAN), gateway, or link server (MAXLINKS) to foreign systems. It provides for high-resolution graphics utilising a powerful graphical user interface - MAXVUE. The maxDNA also provides a comprehensive set of tools (MAXTOOLS) for the development of system application, configuration and installation.
maxPAC input and output modules connect thousands of process variables, controllable and element devices throughout the plant to the maxDNA Plant Automation System. maxPAC I/O modules are available in a number of input and output configurations to match the electrical characteristics of the sensors, transmitters and controllable devices.
Key Features
High density I/O. Isolated Input / Output modules. Supports full redundancy. Both local and remote installations. Lower power consumption. Self calibrated analog modules. Remove and insert modules while powered. Modules have colour coded faceplates for rapid identification. Rotary address switches for fast set-up. All the modules that require field power include a front mounted fuse disconnect and a LED fuse status indication. All discrete modules include front mounted LEDs for input / output state. (15+1) bit Resolution for Analog inputs.
OPERATING ENVIRONMENT
MaxPAC I/O and related hardware comply with the following standards.
ESD - IEC 801-2. Surge - IEEE-472-1974 (ANSI C37 90a) surge withstand test. RFI-801-3 with the cabinet door closed. Vibration - Sinusoidal vibration specification per SAMA PMC31.1 using control
room level; 1 mm displacement 5-15Hz, 0.5G 15-150Hz. Storage temperature - 26 to 70 Degree C. Operating temperature 0 to 60 Degree C. Relative Humidity; 5 to 90%, non-condensing.
SALIENT FEATURES
- 32 Bit Intel Multifunction Controller for OLCS & CLCS with WINDOWS CE Operating System.
- Multilevel security system are envisaged for different functions like engineering, database changing etc.
- Scan time for critical analog signals is 20 milisec & others 100 millisec or above.
- Execution time for control logics is selectable from 20/100/500 millisec. as per requirement.
- History with 1 second sampling rates and long term storage & retrieval.
- Point database (Global Data) accessible at any station across the Network.
- OPC complaint.
LED Indication
A green LED, labeled Active at the bottom of the module front panel, is on when system power is present and the module is communicating with the DPU. This LED blinks on and off when the module is not being scanned by the DPU.
Bus Address
This module supports two modes of operation selected by jumper setting. For use as a replacement for a Model 564 module this module requires 16 bus addresses and provides 15 channels. The addressing rules specified in the Model 564 manuals still apply. When used as a maxPAC module, the module only requires two bus addresses and provides 16 channels. Each module address must be on an even boundary (i.e. 32, 34 50 etc.) in the range of 32 to 252. Addresses 0 to 31 are reserved for digital input modules.
Module Operation
This microprocessor-based module supports up to 16 isolated high level inputs. A sigma delta A/D and precision reference is provided for each pair of inputs. The A/D reads the voltage generated by the selected input and converts the differential measurement to a 15-bit plus sign binary value representing the voltage input, which is read by the microcontroller. The microcontroller initiates the conversion and waits for the conversion to complete. The digital filter in the oversampling A/D provides excellent 50/60 Hz normal mode rejection. Prior to starting each conversion, the microcontroller selects one of the two input channels by means of two solidstate, optically coupled relays. The two inputs are multiplexed with optical relays to provide channel to channel isolation. Immediately following each measurement, open input and over range conditions are checked. A separate DC/DC converter provides isolated power to each A/D converter measuring circuit. Communication between the microcontroller and each A/D is serial at 100KHz. A separate group of optical isolators provide the isolation between each A/D and the serial logic circuits. The microprocessor provides the input data to the DPU on demand via the bus FPGA. The FPGA provides the I/O bus interface logic; its program is loaded from the FLASH on power up. Module calibration is done automatically at power up following startup diagnostics. Calibration is repeated periodically online to compensate for temperature effects.