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Instruments & Controls

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Plant Data That Promotes Optimization• Energy usage computed by degree day• Efficiencyoftheplantandeachboiler/furnace• Totalsteamgeneratedbytheplantandeachboiler• Totalfuelusedbytheplantandeachunit• Average cost of steam• Equipmentcycletimesandoperatinghours• CondensateTemperaturetohelpidentify“blowntrap”• BlowdownMonitoring• Make-upwaterflowvs.totalfeedwaterorsteamflow• FlueGasOxygenvs.SetpointMonitoring,etc.

Boiler Diagnostics• Boilercontrolandflamesafeguardalarmandequipment

statusinformationarepresentedbothgraphicallyandonalarmandeventsummaries.Thisaidsintroubleshootingthecauseoftripsandpotentialtrips

• Remoteequipmentmonitoringallows forpreventativemaintenance.Problemscanbeevaluatedcentrally,allowingtechnicianstocomeproperlyequippedtotheremotesite

Unsurpassed Availability• PreferredPCC-III, PWC, FSC, and BMU controllers provide

continuedplantoperationintheeventofaControlNetworkand/orSCADAshutdown

• MultipleSCADAServersprovidecontinuedoperationintheCentralControlRoomintheeventofaSCADAshutdown

• Dedicatedboilercontrollersprovidecontinuedremoteandlocaloperationofunaffectedboilersintheeventofasinglecontrollershutdown

Lower Installation and Commissioning Cost• ControllerTuningScreensandHistoricalTrending tools

helpspeedcommissioning• ControllersandI/Owiringarelocatedneartheequipment

tosaveinstallationcost

SCADA/Flex is a Robust Plant Optimizing SolutionTheabilitytomonitorandcontrolplant-wideprocessesfromasinglelocation,whilealsocollectingandsharingreal-timeplantdata,hasbecomean invaluable tool for improvingthe operation of boiler plant equipment. Plant ownersaround thecountryhavesuccessfully turned toSCADA/Flex fromPreferred Instruments.SCADA/Flexhelpsyouturnplantoperatingdataintoinformation,andinformationintodramaticallyimprovedperformance.

Overview GraphicsOverview graphics are provided tomatch the specificsof your plant. Each screen intuitively displays criticalinformation for quick andeasy operation. “Soft buttons”provideanintuitive“pointandclick”interfacefornavigatingbetweenscreens,acknowledgingalarms,andcontrollingequipment.

SCADA/FLEX DISTRIBUTED CONTROLOverview

SCADA/Flex Offers:• Processvisualization(HMI)• SupervisoryControlAndDataAcquisition(SCADA)• Localorremoteoperatingmodes• HistoricalTrending• Alarming,alarmmanagementandprinting• ReportGenerationandPrinting(Option‘-R’)• Highperformancenetworking(Ethernet&FiberOptic

optional)• Interface toFireyeandHoneywellFlameSafeguards

(optional)Quanta-FlameFlameSafeguards• DevelopmentSoftwareallowscontinueddevelopment

onsite(Option‘-DS’)

Open Architecture for Third Party Applications (optional)SCADA/FlexcanactasanOPCServertoanystandardOPCClient.Alternatively,SCADA/FlexcanactasanOPCClienttoanystandardOPCServer.SCADA/FlexleveragestheODBCApplicationProgrammingInterface(API),addingthecapabilitytocollectandwritereal-timesecureelectronicrecordstooneormorerelationaldatabases.DatacaneasilybemovedbetweenarelationaldatabaseandtheSCADA/Flexprocessdatabase.

Historical TrendingMulti-colored strip charts display of any group of eightvariablesforanylengthoftime.TheZoomfeatureandadatacursorallowprecisereadoutandcomparisonofanyevent.Datamaybeplacedonaserverorflashdriveforlong-termstorageandcanbereloadedatanytimeforanalysis.

SCADA/Flex Workstation



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SCADA/FLEX DISTRIBUTED CONTROLOverview

Report Generation (Option ‘-R’)Intelligentreportstabulateandsummarizetohelpidentifytrends in efficiency.Energy use can be comparedwithprevious reports to spot potentialwaste or to verify theeffectiveness of fuel saving strategies. Plantmanagerscaneasilyrunreportsonkey“performanceindices”such as cubic feet of fuel burned per degree day.Carefuldatatracking coupledwith the intelligent control of processsystemshelps produce significant energy cost savings.Shift,daily,weekly,monthly,andyearlysummaryreportsareautomaticallygeneratedandcanbeprintedatanytime.

Centralized Plant Operation-Local ControlTheSCADA/FlexSystemprovidestheeaseandflexibilityofcentralizedplantoperationwhileensuringthesafetyoflocalcontrol.Workstationscanfullyoperateanentireseriesofplants,onsiteoracrossthecountry,throughdial-uporleasedline.SCADA/Flexsystemscanevenbeoutfittedwithlaptopssothatmonitoringandcontrolcanbeadministeredwhiletraveling.However,PCC-IIIandPWCcontrollerlocaloperatorinterfacesallowplantoperationintheeventofaworkstationand/ordatahighwaymalfunction.

PlantOverviewDisplay(s)At-a-glancemonitoringofboilerplant

HistoricalTrendingDisplay(s)Anessentialmonitoringtool.Multiple(8)pen“Charts”

AlarmDisplayAlarm, events andoperator actionsareloggedwithtime/datestampand

description

TuningDisplaysTuning parameters are presented alongwith process variable trends to facilitate

commissioningandmaintenance

ControlDisplay(s)Intuitiveworkstationcontrolmimicslocalcontrollerstomaximizeeaseofuse

BoilerOverviewDisplay(s)Fasterandimprovedunderstandingofboileroperation

Intelligent Reports



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HardwareProcessor: IntelXeon1.8GHzorbetterMemory: 8GBRAMDrives: 600GBHardDrive,DVDROMDriveMonitor: 24"FlatPanel

(Computerhardwareofferingswillbeupdatedasnewequipmentbecomesavailable.Ajob-specific,detailedproposalwillincludedetailsonthecomputerandperipherals.)

SoftwareHMIGraphics:Object-orientedPlatform: IntellutioniFIX,MicrosoftWindows,VisualBasicforApplications(VBA),MicrosoftExcel®forReportsArchitecture: RealtimeClient/Server,OLEforProcessControl(OPC)Integration: SQL/ODBCAPI,OPCto/fromthirdpartyOPCClient/Server(optional)

Security: ConfiguredandsynchronizedwithWindowsControlNetwork

Medium: RS485StandardandEthernet(FiberOpticoptional) Protocol: Modbus(ASCIIorRTUmode)Printers

Alarms: DotMatrixReports: DeskjetGraphic(includedinReportGenerationoption)

UPSRating: 800VA(~30minutes)

OrderingInformation

Description (select any combination)

CatalogNumber

ChiefDispatcher(specifyquantityofBoilers“-#”) add “-CD” suffix

UtilitySaverBurnerControlSystem(specifyquantityofUtilitySaverSystems“-#”) add “-US” suffix

BurnerMateBoilerControlSystem(specifyquantityofBurnerMateSystems“-#”) add “-BM” suffix

Optional Features CatalogNumber

ReportGeneration(Optionincludesreportdeskjetgraphicprinter) add “-R” suffix

DevelopmentSoftware(ConfigurationSoftware) add “-DS” suffix

CatalogNumber:SCADA/Flex - CD8 - US4 - BM4

AdditionalOrderingInformationOnly“basic”systemorderinginformationisprovided.Pleaseconsultfactoryforthefollowing:• AdditionalInputandControlrequirements,BalanceofPlant,etc• AdditionalSCADA/FlexServersorClients• RemoteSiteMonitoring• EthernetorFiberOpticControlNetworks• Interfacestothird-partysystemsorprotocols• SQL/ODBCAPIIntegration

SCADA/FLEX DISTRIBUTED CONTROLSpecifications



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SCADA/FLEX DISTRIBUTED CONTROLSuggestedSpecifications

1. ApplicationProvidearemoteSupervisoryControlAndDataAcquisition(SCADA)systemdesigned toprovide remoteoperation,graphicdisplayofinformation,alarmmessagedisplay, reportgeneration,historicaltrendingandremotecontrollertuning.TheSCADAsystemshallbenetworkedtotheboilercontrolandburnermanagementsystems.2. Equipment RequirementsCommunicationsbetweenthedataacquisitionsystem,theindividualcontrollers,andflamesafeguardsshallbeviaanindustrystandardprotocolsuchasModbus.3. Equipment Hardware FeaturesThesystemshallusestandardIBMPCcompatiblehardwaretosimplifyfutureexpansion,replacementandservicerequirements.Providethefollowingworkstationhardwareataminimum:IntelPentiumIVmicro-processorornewer,2GBRAM,80GBHardDrive,32bitSVGAvideocontroller,2"FlatScreenMonitor,3.5"FloppyDrive,DVDROMDrive,keyboardandMicrosoftmouse,towercaseforcomputer,alarmprinter,tractorfeed9pindotmatrixprinter,shiftreportandtrenddeskjetprinterand1000VAUPSbackuppowersystem.4. Equipment Software FeaturesThesoftwarepackageshalloperateinconjunctionwiththeMicrosoft7operatingsystem.ReportsshallbepreparedautomaticallyusingstandardMicrosoftExcel®spreadsheets.Softwareshallbecontrolledbymousebased toallow foreasyselectionofscreens,manual/automaticstatuschanges,start/stopfunctions,setpointchanges,andoutputchangeswithoutanyspecialprogrammingskills.Thesystemshallbeexpandableinthefuturetoamulti-workstationsystemviastandardEthernetLANhardware.AnymeasuredorcalculatedvalueshallbeavailabletothirdpartysoftwareviastandardOLEforProcessControl(OPC)DataExchangeasanoption.ProvideallnecessarysoftwaretoallowfieldtheDataAcquisitionsystemtobemodifiedorexpandedinthefield,includinggraphicsdrawingprograms,databasebuilders, reportgenerators,etc.Systemsbasedon“run timeonly”programswillnotbeacceptable5. Human Machine Interface (HMI) Terminal OperationTheoperator,whenthelocalcontrollersareenabled,shallhaveremotecontrolofthefollowingfunctionsfromthedataacquisitionterminal:Manual/Automodeofeachcontroller,Controllersetpoint values,Controlleroutputwheninthemanualmode,PIDtuningparameters,Controlleranalogoutputvalues,Controllerdiscreteoutputvalues.TheHMIdisplayshallprovideafacsimileofthelocalcontrollerandclearlylabeledEnglishlanguageandengineeringunitdisplayofthecontrolparameters.Nospecialprogrammingskillsshallberequiredforanyroutineoperatingsequence.

6. Graphic DisplayInformationshall bedisplayedon theHMIaspart of aneasilyunderstoodpictorialrepresentationoftheprocess.Atminimum,thefollowingpictorial “screens”shallbeavailable forobservation: forexample,atypicalsteamgeneratorwoulddisplay(whenavailable):steamdrumpressure,steamflowforeachboiler,steamtemperature,drumwaterlevelsforeachboiler,flamefailure,fuelflows,combustionair temperature,fluegas temperature,boilerefficiency (byASME“losses”method),Airflow,Fluegas recirculationdamperposition,Outletdamperposition,ControllerFaceplateGroupingforeachboiler,TrendScreensforeachgroupofcontrolledandprocessvariablesasrelatestoeachcontrollerinthesystem.Allvaluesshallbedisplayedinengineeringunitsadjacenttothepictorialpointofmeasurement.7. Remote TuningEachcontrollerinthesystemshallbecapableofremotetuningofgain,reset,rateandotherimportantparametersviatheSCADASystem.Tuningthecontrollersshallbea“menudriven”operationandshallnotrequirespecialprogrammingskills.Wheneachcontrollerisplacedintheremotetuningmode,arealtimetrendchartofcontrollerinputsshallbedisplayedon theHMI toaid the technician insetting theproperparametervalues.Thisfunctionshallbepasswordprotectedforsecurity.8. Alarm GenerationWhereapplicable,alarmstatusshallbedisplayedon themonitorgeneratedprocesspictorials.Inaddition,allalarmsshallbeprintedastheyoccuronthealarmprinter,anddisplayedonthelowerportionofeachHMIdisplay.Thealarmlog,asgeneratedattheprinter,shallindicatethetimeatwhichthealarmoccurred,thetimeatwhichthealarmwasacknowledgedandthetimeatwhichthevaluereturnedtonormalstatus.Inadditiontoalarmconditions,this logshallalsodocumentstatuschangessuchasatransferfromautomatictomanual,setpointchange,etc.sothattheresultantprintoutisatrueandcompletelogofplantoperatingconditions.9. Report GenerationThelogsheetprintershallprintout:ondemand,shift,daily,weekly,monthly,andyearlyplantoperatingreportsforevaluationbytheplantmanager.Asanexample,forasteamgeneratorapplication,areportwouldlist(whenavailable):1. Totalsteamgeneratedbytheplantandeachboiler2. Totalfuelusedbytheplantandeachboiler3. Averagecostofsteam4. Input-Outputefficiencyoftheplantandeachboiler5. Items1through4shallalsobereportedona“perdegreeday”

basiswhereapplicable6. Combustionefficiency(byASME“ByLosses”Method)foreach

boiler7. Make-upwaterflowinpoundsandalsoasapercentofsteamflow8. Hoursofoperationforeachboiler9. Steamflowtoeachofthedistributionheaders



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SCADA/FLEX DISTRIBUTED CONTROLSuggestedSpecifications

10. Historical TrendingThesystemshallbecapableofstoringthevaluesfromalltransmittersaswell as system computed values (such as efficiency andcompensatedflowrates) toharddiskatselected intervals.Storeddatacanbedownloadedtoaninternalharddrivetoarchiveorreloadintothesystemforanalysis.AlldatastoredinthesystemshallbeavailableonHMIorpaperplotdisplaysasstripchartrecordswithuptoeightchannelsperdisplay.Thehorizontalandverticalaxesofthetrenddisplaysshallbevariabletoprovidethedegreeofovervieworfineresolutionrequiredforeachspecificanalysis.Thesoftwarepackageshallbepre-programmedtogivetheoperatora“menu”ofstandardtrenddisplays.Ifacustomdisplayisrequired,theusershallbeabletogeneratetherequireddisplayviahelpmessagesanda“fill-in-theblanks”menu.Nospecialprogrammingskillsshallberequired.11. Flame Safeguard InterfaceTheSCADAsystemmayhavededicatedcommunicationsbetweenthecomputerandtheFlameSafeguardsystemssoastoallowallalarmstobegraphicallyrepresentedonthemonitor.Thesystemmustbecapableofdisplayingandrecordingthefollowingstatistics:burnerlimits,individuallockouts,burneroperationhours,totalburnercycles,burnerstatus,lastsixlockouts,totallockouts,andflamesignalstrength.

12. Data Acquisition System CompatibilityTheSCADASystemmaybeexpandedtocoverotherplantutilities.ItisthereforeessentialthattheSCADASystemsuppliedforthisprojectbe“open”andeasilyadaptabletootherbrandsofcontrollers,sensorsandI/Ohardware.Atminimum,thesystemsuppliedunderthiscontractmustbeabletocommunicatewith3separatecommunicationlinkssimultaneously. Thesystemmusthaveavailablecommunicationdrivers for:FireyeandHoneywellflamesafeguardsandPreferredInstrument PCC III and PWCControllers.ThesystemmustnotbeproprietaryordedicatedtoasinglebrandofcontrollerorI/Ohardware.13. Quality AssuranceAllcontrolfunctionsshallbeaccomplishedwithintheindividualBoilerControlandBurnerManagementcontrollersandshallbemonitoredbytheSCADAsystemsothattheintegrityofthecontrolsystemshallnotbedependentonthestatusoftheSCADAsystemortheinterconnectingnetwork(Intheeventofacontrolnetworkand/oraSCADAshutdown,localcontrollersmustcontinuemonitoringandcontrollingtheplant).TheSCADAsystemshallbeaPreferredInstruments,Danbury,CT,SCADA/Flex.