EOS EUAS Automation Systems

WHY ARE EOS STUDIES NEEDED?

The developments in the information sector in recent years have led to the rapid development of automation systems technologies, as in many areas. Automatic control systems have become indispensable components of today's industrial applications.

Thanks to the application of programmable controller-based automation systems to industrial facilities in parallel with the development of microprocessor technology many benefits such as realization of process-oriented control, monitoring of many parameters and their effective control, reduction of costs, increase in quality, efficiency, operator safety and production levels, general optimization, ease of operation and maintenance can be achieved. In the electricity generation portfolio of our organization, there are still many electricity generation facilities operated with relay-contact systems.

Replacing the control systems in these facilities with modern systems will greatly benefit our Corporation in terms of efficiency and profitability. On the other hand since digital control systems have a certain economic life and these technologies change and develop very rapidly, facilities having these systems should be rehabilitated with up-to-date digital control systems at regular intervals. It is important to use effective engineering methods during the conversion of relay control systems to digital control systems. Our organization has realized some renovation projects for this purpose and is planning to realize new projects in the coming years.

WHAT ARE THE OBJECTIVES OF THE EOS PROJECT?

Within this Project;

Designing the automation systems used in the production facilities of EÜAŞ with institutional opportunities,
Realization of the control and automation systems of the facilities within EÜAŞ that do not have automation and SCADA infrastructure with in-house opportunities,
Implementation of the designed system in a small-scale pilot plant, then applying it to all production facilities,
Reducing the dependency of EÜAŞ on external resources, which are often extremely costly, in automation systems components,
Making EÜAŞ power plant automation systems more flexible against possible cyber attacks aimed at energy automation,
In parallel with the development of microprocessor technology, many benefits such as process-oriented control, monitoring of many parameters and their effective control, general optimization, ease of operation and maintenance, thanks to the application of programmable controller-based automation systems to industrial facilities,
Developing in-house resources and engineering capacity of EÜAŞ in automation systems,
Establishing institutional standards for automation systems and ensuring that systems developed by internal resources are used as standard components in EÜAŞ facilities,
Determining with our trained human resources that can be used during the meeting of rehabilitation or renewal needs,

have been intended.

WHICH PRODUCTS HAVE BEEN DEVELOPED WITHIN THE SCOPE OF THE PROJECT?

There are many software and hardware products put forward by subgroups within the scope of the project.

EÜAŞ Automation System consists of an integrated combination of different elements such as EOS hardware, control computers, Scada software, engineering program, controller software, network infrastructure for data communication, communication protocols, databases and cyber security infrastructure.

WHAT ARE THE HARDWARE PRODUCTS RESULTING FROM THE PROJECT?

EOS hardware consists of communication, digital input, digital output, analog input, analog output and power supply modules. EOS Hardware also includes a communication data bus that enables data transfer between EOS modules, which we call BUS infrastructure.

The design of EOS hardware products has been carried out step by step, using worldwide accepted design methods so as to be conceptual, basic and detailed design.

In all design stages, importance was given to isolation and protection, the thickness of the roads was calculated and drawn according to their current carrying capacity, and measures to prevent electromagnetic noise were added to the design. Care has been taken to ensure that the circuit elements on the hardware cards are easily accessible, and that the circuit elements and circuit paths are generally properly placed.

In addition, the fact that all hardware products are economical and manufacturable is among the features to be considered. The features of each of the EOS hardware modules are described below:

Communication Module

It has been designed to provide data exchange between CPU and input/output cards. With its 25W power section, it can provide the necessary supply for a hardware shelf. It has all the circuit components that perform the data exchange between the Media Access Controller (MAC) and the physical ethernet layer within the micro controller (MCU) according to the Media Independent Interface Standard (RMII). It operates at a speed of 100 Mbps with a 50 MHz clock signal. The module cycle time is 16 microseconds (μs).

Digital Input Module

This module, which is used to receive the digital values coming from the field to the control system, is designed as 16 channels. The CPU side is isolated from the field with a digital isolator with an isolation level of 2500V. It has a cable break diagnosis feature that can be activated from the CPU. There are 2 Fast Counter inputs (CH1, CH2) and 2 AB Encoder inputs (CH3-CH5, CH4-CH6). The module cycle time is 8 microseconds (μs).

Digital Output Module

This module, which will control the units that need to be controlled digitally in the field with the signals it receives from the CPU, has 16 digital output channels. The CPU side is isolated from the field with a digital isolator with 2500V isolation level. It has cable break and overcurrent diagnosis that can be activated from the CPU. It has 4 pulse width modulation (PWM) features. The module cycle time is 10 microseconds (μs).

Analog Input Module

Designed as 4 channels of 16 bits, this module offers the opportunity to measure analog current and voltage values from the field. Each channel is isolated from each other with a 1500V isolation level. The CPU side is isolated from the channels with a digital isolator having an isolation level of 2500V. It has cable breakage activated from the CPU, under-limit and over-limit diagnosis features. The module cycle time is 7 microseconds (μs).

Analog Output Module

This module, which consists of 4 channels of 16 bits each, provides the necessary analog current and voltage values for the control of the equipment in the field. Each channel is isolated from each other with a 1500V isolation level. The CPU side is isolated from the channels with a digital isolator having an isolation level of 2500V. It has open circuit and short circuit diagnosis feature that can be activated from the CPU. Current and voltage outputs can be used without the need to change the connection. The module cycle time is 8 microseconds (μs).

Power Supply Module

It has a total power supply of 50W. The same design can also be used as 25W when needed. The CPU side is isolated from the channels with a digital isolator having an isolation level of 2500V. The module cycle time is 2 microseconds (μs).s).

Communication between EOS modules is carried out over a communication data bus called the EOS BUS infrastructure.

An example hardware rack on which EOS boards are combined in a single-rack infrastructure is shown in the figure below.

WHAT ARE THE SOFTWARE PRODUCTS RESULTING FROM THE PROJECT?

A series of controller software is needed to perform plant automatic control with EOS hardware. These softwares should not only enable the implementation of automation algorithms for facility control, but also fulfill the function of communication with secondary hardware, and also act as a bridge between Scada software and hardware.

It is also important that the algorithms running on the controller software can be easily edited by the end users, the algorithms run by the controller can be monitored and the configurations of the EOS hardware can be performed.

The EOS controller software listed below serves to provide the functions listed above.

EOS Engineering Software

It is the program in which the algorithms required for industrial facilities to be controlled by EOS are created. Thanks to the algorithms created with the engineering software, it is checked whether the information coming from temperature, pressure, voltage, flow and all similar sensors meet the necessary conditions, and the facility is controlled by using the input/output information coming from the analog and digital input/output cards, thanks to the logic gates operated by the Controller Runtime software.

Algorithms used for the control of the industrial plant are created in the form of a function block flow chart. Algorithms designed to be simple and understandable offer a more practical and visual structure compared to other methods (Ladder, STL) used in DCS and advanced PLCs. Thanks to the compilation feature, the errors made by the user in the program can be detected and the user errors are automatically corrected.

EOS Controller Runtime

It is a controller software that provides facility control by interpreting the algorithm command lists produced by the engineering software, with the signals it receives from and sends to analog and digital cards. It can simultaneously communicate with Engineering Software, Configuration Software and Scada software.

The Controller Runtime software running on industrial PCs is designed independently of the switchboard. Controller Runtimes, which operate differently on a unit basis, can communicate with each other through services, and can be easily adapted to systems that will operate with redundancy, since they process the command list sequentially.

More than one communication protocol (Q Service, Modbus, SQL, Text) has been added to the Controller Runtime software to communicate with other programs and systems. With the improvements made on the Controller Runtime software, the command processing cycle time has been shortened considerably.

EOS Hardware Configuration Software

It is software developed for configuration of EOS hardware modules. It can work simultaneously with the Controller Runtime software in order to make special settings for the switchboard. The set values set by the configuration software are read by the Runtime software and facility-specific operations are provided.

The configuration software provides the opportunity to recognize EOS cards automatically and the operator to monitor the cards simultaneously.

The software can scan all electronic cards in milliseconds and check whether there is any communication or electronic malfunction. It facilitates the detection of card and channel faults by performing online hardware monitoring. In addition to faults, active channel and instant input/output information can be monitored.

PWM adjustments for sensors such as positioner and tachometer in digital channels and 4-20mA, 0-10V adjustments, offset and calibration settings for analog channels can be made easily with the help of the configuration software.

EOS Scada Software

EOS Scada software is a software package consisting of sub-components developed to meet functions that are important for facility automation, such as creating human-machine interface screens for a facility control, using these interfaces for facility control, archiving data regularly and providing easy access to the archived data throughout the facility. The following sub-components exist in The EOS Scada software package:

EOS Scada Editor,
EOS Scada Runtime,
EOS Data Explorer and
EOS Historian/Data Logger.

Each of these subcomponents is described below.

EOS Scada Editor

Editor has been developed for the design of the Scada system necessary for a facility to be controlled by the EOS automation system. With the help of the Editor, all the definitions required for the Scada system can be entered, stored, edited and the designs can be further developed over time with the help of a project database.

Editor software allows working with more than one project at the same time and each project information can be organized in separate folders. Thanks to the Editor software, it is possible to switch between projects quickly.

Editor software, which has data simulation feature, can provide rapid testing of created designs. It facilitates screen visual design with functions such as cut, paste, move, delete, undo, repeat, grid structure, align.

In addition, it can store and recall design information, create instant design snapshots, and provides the opportunity to return to any snapshot.

It enables the preparation of libraries in groups from the created visual elements, thus creating block modules from the visual elements and quickly calling and using these modules during screen designs. Thanks to its general and project library feature, it allows to carry visual components both within the project and between projects. Many useful tools have been added to the Editor to make the work of Scada designers easier.

EOS Scada Runtime

Runtime has been developed to monitor and control the facility by using definitions created by the Editor. With the help of device drivers, it can perform data communication with different devices, primarily EOS hardware, with the help of common protocols such as MODBUS and OPC.

It enables the collected data to be watched on screens enhanced with rich visual and audio features, archives the data and enables easy access to the archived data.

In addition to monitoring alarms and events, it can communicate the necessary warning mechanisms to the facility operating personnel with the help of visual and audible elements. It can archive the alarms and events that occur and enable the operators to access these archives quickly.

With its 4-level authorization infrastructure, namely Monitoring, Operation, Engineering and Super User, it enables the operation personnel to perform operations according to their authority, and helps to archive all the commands given to the facility by the operation personnel.

It facilitates shift change in shift systems with the help of double login feature.

Runtime software can publish the data that it collects from the hardware in widely used formats such as MODBUS, JSON, XML with the help of embedded servers. Runtime software is equipped with many additional features to facilitate the work of plant operating personnel.

EOS Data Explorer

It is an EOS Scada sub-software that enables end users to access archived data from any computer connected to the Scada network.

It makes the archived data understandable for end users, enables the preparation of comparative graphics with these data, exports the data as CSV and performs the analysis on the data.

An example architecture for field use of EOS Scada software is given in the figure below.

IN WHICH FACILITY WERE THE PRODUCTS RESULTING FROM THE PROJECT TRIED?

Kepez II Hydroelectric Power Plant, which is affiliated to the EÜAŞ Antalya and Region Operations Directorate, was selected as a pilot facility for the studies on the developed system. Kepez II Hydraulic Power Plant is a small-sized power generation facility with an installed capacity of 2x3 MW, which was put into service in 1986.

Within the scope of pilot studies, data lists, Scada screen designs, field algorithms for Kepez II HEPP were created and tested.Panel assembly project drawings, panel and field wiring, field assembly studies were completed and the system was successfully installed in Kepez II site and put into use.

In the preparation of the Scada screens, the drawings closest to the appearance of the switchboard equipment were used, as it was thought to be encouraging for the end users. Considering factors such as simplicity and long-term use in screen designs, care was taken to make user-friendly designs.

The EOS System has been continuously monitored by the EOS project group since the day it was established in Kepez II Hydroelectric Power Plant, additional studies are carried out on issues that require development, and the system has been operating without any problems until today.

WHAT IS PLANNED FOR THE PROJECT IN THE FUTURE PERIOD?

EÜAŞ Automation Systems development studies continue uninterruptedly. Nowadays, planning for the next 2 years is being carried out.

In this context, processor cards with fast-response time, PT100 temperature card, 8-port analog input-output cards, smaller versions of EOS cards that can be applied to switchboard subsystems, variants of input cards that can be used in switchboard status monitoring systems such as vibration monitoring are considered as priority hardware projects.

On the other hand, LINUX-based embedded controller software, advanced engineering and Scada software systems are among the software products to be worked on in the new R&D period.

In the new period, the establishment of a cyber-security workshop, further strengthening of automation systems in terms of cyber security, and the development of our corporate high-security and encrypted communication protocol are among the planned works.

This page updated at 1 Ağustos 2023 13:17