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1 Project Overview The Zhejiang Zhenhai United Power Generation Co., Ltd. (hereinafter referred to as Zhenhai United) 300MW combined cycle power generating unit was started construction in 1996. The entire project was designed by the British John Brown Company. The unit was officially put into production in 1998. The DCS control system of this project adopts the INFO-90 system of ABB, and the original DCS console consists of three OIS25.3 series operation stations. After a long period of operation, the failure rate has gradually increased. Frequent crashes in the operation console and damage to components have occurred. At the same time, there are problems such as high maintenance costs and difficulty in procurement of spare parts. In 2003, the operator's platform was upgraded for the first time. ABB's Conductor NT solution was used to upgrade three of the 0IS25s to Conductor NTs, and the replaced OIS25s were used as spare parts for the other two. In 2007, ABB's Power Generation Portal was adopted to perform a second comprehensive upgrade of the operator station. At present, the operator station uses three Power Generation Portal servers and three Power Generation Portal clients.
2 DCS operator station reconstruction program to determine the original DCS operator station (01S25) from production to 2003, has been running for more than 8 years, the main parts of the operator station due to aging has repeatedly crashes and other failures, and some parts have stopped production , resulting in difficult to purchase spare parts and the price is very slim, for example, the original backup tool for operator station data backup can not be purchased, resulting in the operator station data can not be backed up, this is not only a great security risk, but also restricted DCS will improve and expand in the future. The upgrading of DCS operator stations is imperative. As the operating units are not as long as the newly-built units have a longer rebuild period and a longer commissioning and commissioning time, the operation platform modifications must be completed within a month by the crew. The duration is relatively tight. In addition, immediately after the completion of the transformation, the unit needs to be commercialized. It must ensure that the transformation is successful at one time, and the pressure on safety is also relatively large. For the operating personnel, due to the lack of sufficient study time and over-adjustment period, there are also various unsafe ones. factor. Therefore, the escalation strategy adopted by the author is to transform the operator station step-by-step, that is, one of the three OIS25s is upgraded, and the replaced OIS25 device is used as another two spare parts. This will not only solve the original 01S25 spare parts problem, but also enable operators to obtain a longer period of learning and adaptation period.
In 2003, the operator station was reconstructed for the first time. At that time, few options were available. In order to balance the safety factor of transformation and future technical support, A13B's ConductorNT and ABB Bailey were used to solve their traditional operator station problems. In 1997, Conductor NT was developed based on the newly acquired HSCHER&PORTER S6000 monitoring software and its own 90-communication drive software. ConductorNT is connected to the interfaces of PLANTLOOP and NHNET. Data can be exchanged through the serial interface or SCSI interface. Many functions are added. The functions of the engineer station can be realized by loading the engineer station program.
In 2007, the second upgrade of the operator station was carried out, but instead of using the Conchictor_ solution, ABB's Power Generation Portal solution was used. The reasons are:
(1) ABB's Conductor NT original operator station graphics and labels cannot be converted and upgraded, and must be manually reworked during the renovation. The maximum number of errors in the project is apt to cause errors. The details cannot be considered comprehensively. The original OIS25, alarm chaos is relatively chaotic and operational reliability is poor:
(2) ABB's ConductorNT's own shortcomings: historical data management functions are not strong enough, data can only exist for about a week, openness is not good enough, etc.
(3) After ABB launched the new operator station after 2003, its software is no longer developed and upgraded. In the future, it will face the problems of spare parts and technical support earlier.
ABB's Power Generation Portal, ABB's 2003 DCS operator station based on the Tenore software, also replaces the 90-system operator station. It adopts a full range of redundant server/client architectures; it has a database kernel feature that enables it to have powerful historical data and event acquisition and storage capabilities. It can also be used as a historical station and an engineering station, with highly integrated information and tag capacity. Large, fully open interface, easy to use, support for the conversion of the screen and tag database, using fully open OPC, MODBUS, ODBC.TCP/IP and other standard communication protocols and application standardization technology to support third-party software and standard interfaces , It can be developed into a common platform for multiple information aggregation, and it is constantly upgraded and perfected due to its late launch.
3DCS operator station transformation implementation 3.1 Fully redundant server/client structure Realization Zhenhai joint factory configuration 3 PGPServer and 3 PGPClient, 6 operation stations and its interconnection network realizes the redundant configuration completely. 
As shown in Figure 1, the hardware stations in Taiwan and Taiwan are installed with redundant Ethernet NICs and are connected to the switch through RJ45 cables. The two switches are redundant by using jumper cables. Any client operator station can be connected to any one of them. Server operation station, in which one Server operation station fails, the Client operator station connected to it can automatically switch to other Server operation stations. The switching time is short and does not affect any operation. In this way, only one Server operation station can work normally. , can guarantee the normal operation of 3 Clients, thus guaranteeing the normal operation of the system.
3.2 The implementation of the historical station PrP Srver normal tag library capacity is 15000 points, of which 1000 points historical storage capacity, but PGP as a historical station, its historical library capacity can be extended to 15000 points, historical station and ordinary PGPServer ^ difference is only The LISENCE of the software is different. The historical station is also a PGPServer. The three PGPServers configured by the factory include the station history station. Because the factory's total tag library is not large, all DCS tags are designed to be saved using a historical library. The PGP system automatically archives alarm information and trends on a daily basis. Under normal circumstances, PGP can view data for a week, and more than one week's worth of data can only be viewed after PGP's program HISTORY returns historical data. The storage time of the PGP is only limited by the capacity of the hard disk of the operating station, and it can fully meet the requirements of the historical station.
3.3 Conversion of the original OIS25 screen and tag database Importing the Beijing OIS25il picture and mark data library is converted by the engineer software COMPOSER. The tag database can be exported from the operator station or the original engineer station. Because the factory lacks the original console data backup tool, the number box is exported from the original engineer station. The tag library of the engineer station and the station tag library are not completely synchronized, which increases the workload. Exporting the label format and contents from the original engineer station is not exactly the same as the PGP. Some of the contents need to be manually input or converted by the tool software.
3.4 Alarm System Improvement The alarm system is an important part of the man-machine interface. The design of the alarm system is the weak link of the DCS application (especially the DCS retrofit project of the old unit). The most basic “list alarm†function of DCS was also left out because it was “not practicalâ€. At present, more commonly used is the use of "light card" auxiliary keyboard, a number of DCS designed a similar form of the alarm screen - "soft light plate", the form close to the operator, the operation will help. However, there are many “soft-light plate†settings, and operators are overly relied on. Other information (such as time, alarm return, etc.) in “listed newspapers†is easily overlooked. The author believes that as long as PGP's filing system is properly configured, all the advantages of "light card" PGP can be achieved, and has the advantage of "light card" can not be replaced.
Zhenhai United Plant divides all signals according to the area where the signal is located into 16 large alarm groups. Each alarm group is further provided with four sub alarm groups. Sub alarm groups are actually divided by alarm levels. The first three levels are defined by the important parts of the signal, and the normal alarm (such as the fault on the measurement) is defined as level 3. The normal operation (such as automatic adjustment, power supply, and important auxiliary equipment tripping) affecting the entire system is defined as level 2. The direct threat to the safe operation of the unit is defined as Level 1. The 4th level is only the normal operation of the unit. No alarm is issued. The definition is to filter all 4 levels out of the alarm list, but archive it in the history database to facilitate accident analysis. Different sound alarms are used when the previous level 3 alarm signal is triggered. Table 1 shows an example of alarm group configuration. The number in the table is the alarm group definition of the tag. 
PGP's real-time alarm system has two ways. One is the minimum alarm window. In the PGP system, three latest reports can be displayed (the number can also be modified by defining the registry). The other is the alarm list. Rich, this system uses the alarm group as the content of the tree structure, similar to WINDOWS's resource manager, supports the alarm content to browse separately by group. When the menu item of the alarm group is not expanded, the status of the alarm signal at the most level below the group can be displayed, similar to the function of "light card", which is very intuitive.
The light plate only has the function of reminding the keyboard. When the big alarm signal occurs at the same time, the light plate only includes some important alarms, and before and after the alarm can not be distinguished, the fault diagnosis still needs to rely on the DCS, and the PGP group the alarm according to the system, alarm The content is displayed comprehensively and accurately displays the alarm triggering time, which not only avoids the difficulty of distinguishing due to the excessive number of alarms, but also facilitates the rapid diagnosis of the fault. In addition, PGP also has other functions such as alarm screening, filtering, etc. that are also impossible to implement with optical characters.
The key to the PGP alarm system is the correct definition of the DBF of the DCS tag library. Although this work is still more complicated, because the PGP tag library is a DBF format file and supports offline configuration, the tag library can be gradually improved.
3.5 Application of PGP and third-party software communication DCS and third-party software PGP use completely open OPC, MODBUS, ODBC, TCP/IP and other standard communication protocols and application standardization technologies, support third-party software and standard interfaces, and can be developed into a variety of The common platform for information aggregation.
For example, the installation information of the excitation system of the three units of Zhenhai United Plant adopts PGP's MODBUS RTU function to directly establish communication with PGP. This method is relatively flexible and low cost. The serial port of PGP can be extended through Nport, so that the serial port of PGP can be connected at the same time. Multiple devices. A connected serial port is connected to the excitation system of different units at the same time. In PGP, only the tag library that defines the registry and communication signals can be implemented, as shown in Figure 1. Our factory PGP and S1S systems also use this method of communication.
In addition, this year, the factory also reconstructed the MARKV1E (combustion engine control system) and DCS communication, added a ring network node, used ABB's BRC410 card to communicate with MARKVIE, communicated via MARKVE and DCSCOMPOSER, and the group of PGP screens. State, so that operators can monitor MARKVIE at the same time in the DCS world.
3.6 PGP Security PGP is based on the WINDOWS operating system. Viruses on personal computers are also susceptible to PGP. This poses great harm to the rectification of DCS systems. Because the whole DCS network is isolated from the outside world, the main way for DCS to infect the virus is to move the storage medium. Personal computers usually use WINDOWS security policy settings and install antivirus software to provide system security. However, PGP's Servei is not compatible with each other's killing software. We install killing software on the PGP Client. Access to PGP data by all mobile storage media is implemented by the PGP of that station, through the PGP's own network to other PGP operator stations. In spite of this, it is still necessary to limit the use of the mobile storage medium as much as possible and to perform antivirus before the mobile storage medium is used. Burning through a blank disc is a relatively safe copy of PGP data.
In order to prevent configuration and data loss, it is very important to perform regular data backup of PGP. I use two methods to backup at the same time:
(1) Through PGP's own network, cross hard disk cloning backup of PGP whole hard disk, the advantage of this is that recovery is very easy when the system crashes.
(2) Backup of the PGP configuration file, the configuration file is exported through the PGP's own tool SYSTEMSETUP. Backup in this way is relatively easy, but you must completely stop the PGP from exiting during data export. Otherwise, the data in the export project is prone to data errors and cannot be imported. This is because there are some default items in the tag library definition. If the PGP system does not stop running, these default items will bring out the actual operating parameters when exporting, and then import them. It will be because these brought out parameters do not meet the format error.
3.7 PGP emulation PGP can be installed on ordinary computers without L1SENCE. This is a great help for PGP learning and familiarity, but it should be noted during installation:
(1) The computer on which PGP is installed must have an English operating system environment, otherwise it may be error-prone during operation;
(2) The PGP sequence can be used for 1 month without LISENCE, but it can be continued by modifying the operating system date;
(3) PGP comes with a signal simulation program that can simulate a single tag or all signals to facilitate viewing the dynamic effects of picture symbols.
4 Lessons Learned The symbols on the OIS25 conversion screen cannot be modified again. To facilitate the DCS in the future, it is recommended to re-establish the standard symbol library.
Although the openness of PGP is good, due to the large degree of freedom of configuration, the workload of the configuration is greatly increased, and more attention is needed to the configuration. For better use, continuous improvement is needed.
Zhenhai 9E gas turbine DCS operation platform reconstruction
Distributed control system (DCS) has been widely used in the thermal control system of thermal power plants because of its high degree of feasibility and powerful functions. Its reliability is directly related to the safety and economy of the unit operation. With the increase of the service life of DCS, the proportion of accidents caused by DCS faults has been increasing year by year. At the same time, a large number of DCS users are facing the problem of DCS transformation and upgrading. This paper takes the reconstruction of the DCS operator station of the Zhenhai gas-steam combined generator set as an example to introduce the solution and experience of DCS operator station reconstruction.