EN-DG-746-145-4001 Rev01

HMI SYSTEM DESCRIPTION
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PROJECT NAME
3 X 660 MW PRAYAGRAJ STPP, BARA, UP
PRODUCT
MAXDNA BASED HMI SYSTEM
CUSTOMER
PPGCL
CONSULTANT
TCE, BANGALORE
BHEL DRG. NO.
EN DG 746 145 4001
WBS NO.
CE / 0746 SH1 56 01
CE / 0746 SH2 56 01
CE / 0746 SH3 56 01
Prepared by :
Arjun Sundar Raj
Checked by
Reetesh Kumar A
Approved by :
A. K. Sinha
Issued by
CE-ENGG / HMI
Date
14/10/2014
Copyright and Confidential:

The information on this document is the property of BHEL. It must not be used directly or indirectly in anyway detrimental to the
interest of the company.
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INDEX
INTRODUCTION......................................................................................... 4
SYSTEM CHARACTERISTICS .5
SYSTEM .. 6
HMI HARDWARE.. 6
HMI SOFTWARE 8
STANDARD APPLICATION SOFTWARE... 9
SYSTEM SCOPE.. 23
PROJECT ENGINEERING... 26

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HUMAN MACHINE INTERFACE

IN
maxDNA
DISTRIBUTED DIGITAL CONTROL
MONITORING AND INFORMATION SYSTEM

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1. INTRODUCTION
The maxDNA Distributed Control System is the latest computer control system to realize
complete power plant automation.
The full maxDNA Distributed Control System consists of one or more maxDNA Remote
Processing Units (RPUs) cabinets containing the following:
maxDPU4F Distributed Processing Units (DPUs), the process controller which provides
control and data acquisition functions.
Input/Output devices (I/Os) for monitoring and controlling the actual process.
One or more maxSTATIONs configured as operator or engineer workstations.
maxNET, a local area network which connects DPUs and maxSTATIONs
Human machine Interface is a system of computers (maxSTATIONs) with associated special
and general hardware components, running real time software. This system of computers is
integrated with the downstream control system, Remote Processing Units (RPUs). Remote
Processing Units are housing Distributed Processing Units (DPU), to maxSTATIONs are
connected through Ethernet switch in a redundant network called maxNET.
An operator may view and manage process control environment through a maxSTATION,
the interface between operator and the maxDNA Distributed Control System. A
maxSTATION may be set up as an Operator's Workstation or an Engineer's Workstation.
HMI runs a set of applications powered by Windows XP Operating system, to realize plant
monitoring and control functions.
The Operators Workstation uses maxVUE graphical interface software to provide a
graphical view of the process. The software uses both standard and custom displays.
The Engineers Workstation is used for creating and maintaining configurations and process
control documentation using the maxDPUTOOLS and maxVUE Graphical Configurator
software. It is also used to create and maintain custom graphic displays using the maxVUE
graphics editor software.

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HMI provides the following functions:

Engineering of the project
Supervision of Plant Processes
Processing of Plant Information
Presentation of Plant Information
Analysis of Plant Events
Operator Dialogue
Monitor based control of the plant (Video process Control)
Long time storage of data for analysis of plant performance
These functions are realized through a variety of displays and reports, which work around
the Process Database and Historical Data. The operator friendliness and the ergonomic color
displays are important features of this system. The operator is guided through a hierarchical
menu of display set, to select a required function or a required picture.
2. SYSTEM CHARACTERISTICS
The main characteristics of this system are:
High speed modern computer systems are at the heart of the system.
Standard computer systems are used to control plants of varying sizes and
complexity.
Windows XP as Operating system.
A set of structured software products, combination of which meets customer
requirements.
Most of the software components are user configurable to provide a customer
specific environment to work with where he is most comfortable.
Windows for operation of plant, display of status and trends.
Mouse for operation of plant.
Network wide printing.

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3. SYSTEM ARCHITECTURE
The HMI system for 3 X 660 MW PRAYAGRAJ STPP, BARA, UP project is configured as
shown in overall configuration drawing of SG/TG/BOP & HMI, EN DG 746 145 5001.
It consists of five Operator Stations (maxSTATION), one TG OWS, 1 electrical draw out
console, 1 no. C&I Draw out console, Six No. LVS Screen, two Engineering Station
(maxSTATION), 1 Shift I/C PC, 1 Performance Calculation PC, 2 MIS PC, Two Storian Stations
(maxSTATION), and One Link Station. These maxSTATIONs are connected in an ethernet
based local area network. A set of switches is used to realize redundant communication
network, called maxNET, for communication between maxSTATIONs and DPUs.
Thus we have a distributed configuration of computer system to cater to the modular
growth, logical distribution of tasks, increased reliability and more choice in configuring the
individual Operator Work Stations. These computer systems perform tasks associated with
facilitating the Operator's dialogue with the Control system like picture call up, issue of
control commands, etc.
4. HMI HARDWARE
The hardware components can be classified into following functional groups:
maxSTATION
These are Operator Stations, Engineer Stations, Storian Stations and Link Stations. This
consists of a PC with Windows XP operating system. These maxSTATIONs are connected
among themselves and also to DPUs via maxNET.
OPERATOR WORK STATION
The Operator Work Station performs all tasks associated with the operator's dialogue with
the Control System. All the software components for the acquisition of data from
controllers, generation of reports, application programs and historical trending are
performed here. Display of control graphics, trends, alarms, historical data, diagnostics, and
reports is done from the Operator workstation.
ENGINEER WORK STATION
Any workstation in the system can be designated as Engineers Workstation. An Engineers
Work Station is used to create, download and edit the control configuration, database and
process graphics.

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Graphics are created and run under a program called maxVUE. maxVUE uses ActiveX
Components for animation.
Control Scheme Generation and database creation is carried out by a configuration software
package called maxDPUTOOLS. It utilizes drag and drop organization, standard graphical
symbols and automatic generation of code.
DATA STORAGE STATION
This station runs a software package called maxSTORIAN. This will collect data for
maintaining history and archiving. Archiving to CDROM is available.
maxLINK STATION
maxLINK runs a software package called maxLINK. This software is used to establish
connectivity with third party systems like PLC over serial link using MODBUS Protocol.
Printers
These are information output devices, used for taking hard copies of data, reports, and
pictures.
maxNET
The maxNET communication system is based on an industry standard open network
architecture providing a 100 Mbps redundant data communications to each drop on the
highway. All the remote processing units and maxSTATIONs connect directly to the
communication network (maxNET).
The maxNET utilizes commercially available standard components, like cables, Ethernet
switches and network interface cards (NICs).
Between the Ethernet switches, the backbone of maxNET communication is 100Mbps, Full
Duplex Fast Ethernet. The bandwidth provided by maxNET exceeds that needed for plant
operation even under the worst case scenario with alarm bursts in few thousands.

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5. HMI SOFTWARE
A number of software components are executed in the computer system for realizing the
various functions of this subsystem.
Some of the important software applications available in HMI System are as follows:
maxVUE Editor
The maxVUE editor is used by engineers to create and maintain custom graphic displays.
These displays are used by the operator to view and control applications. This software
application can be executed only on the Engineers Workstation.
maxVUE Runtime
maxVUE runtime uses the displays created with maxVUE editor. It can be executed in both
the Operators and the Engineers Workstations.
maxVUE is powerful, intuitive, and visually appealing operator interface to the process.
Dynamic data may be displayed with text, colors, shapes or images. System provides for
multiple security levels, allowing flexible control of operator actions. Online context
sensitive help and tool-tips to help operator and engineers are available.
Using maxVUE operator perform following functions
Monitor plant process status
Initiate control actions
Respond to alarm and initiate corrective actions
Monitor system status
Start, Stop and switch to other windows applications.
maxDPUTOOLS
maxDPUTOOLS provides the system engineer with a comprehensive set of advanced
engineering and configuration tools. It allows offline simulation and verification. Selfdocumentation, on line monitoring, and help are inbuilt features in maxDPUTOOLS.
This configuration software package utilizes drag and drop organization, standard graphical
symbols and automatic generation of code.
Point data is stored in MS Access compatible database format. The user may add, delete,
edit, define I/O and their location with regard to DPU, card rack, data highway, plant area
etc. The Database point builder provides for automatic documentation and generation of
code. It also has an extensive library of standard algorithms or objects.
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maxDPUTOOLS can run in Engineers workstation (EWS). It can also be run off line in other
PC and then can be transferred to the EWS.
Software Backplane
The software backplane is the maxDNA distributed communications infrastructure software.
This API, residing on each maxSTATION, is responsible for transferring client data requests
to the provider, which, in turn, provides the data to the client.
The software backplane includes the Real-Time Gateway, the interface to the DPU Module
used to send and receive data from the DPUs in the RPU.
The software backplane also includes the local status server, an application which keeps and
provides information about relevant processes (including reporting any identified alarm
conditions) using the software backplane.
maxSTORIAN
maxSTORIAN supports a historical storage and retrieval system located within Windows XP
workstation. Access to maxSTORIAN is through any of the operator console.
Selected data from the real-time database is periodically stored at a fixed rate in the process
history buffer.
6. STANDARD APPLICATION SOFTWARE

Integrated application in Max Control system is designed to perform the following:
Display functions
Monitoring and Alarming of inputs
Reports and Logs
Historical storage and archiving of selected points
Plant performance calculation
Historical trending
Sequence of Event recording
DISPLAY FUNCTIONS
This function is concerned with concerned with the display and output of
information on the Color Monitors used by the operator.

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Displays are of various types like:
Main Menu
This display provides access to other standard and user created displays.
The Main Menu that comes with the maxVUE Runtime package is really a starting
point for creating custom main menu.
The main menu consists of horizontal and vertical toolbars containing buttons that
open standard displays, such as the System Status display and the Alarm Summary
display. The vertical toolbar also includes an alarm list area. The horizontal toolbar
provides an area for user-defined buttons.
Point data pop-up

This is standard faceplate for each point in the configuration, which allows the
operator to take control actions (mode changes, output and set point changes)
Point Detail pop-up

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The point detail pop-up shows the point configuration data for each point type in the
system.
Alarm Summary
The Alarm Summary lists all active alarms and allows you to filter alarms based on
hierarchical group or point.
System Status Display

The System Status displays show the current condition of networks and the
hardware connected to them.

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Network status Displays

Network status displays show the current status of both maxNET networks.

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Horizontal & Vertical Toolbars

Horizontal and Vertical toolbars provide the alarm list, alarm defeat and restore,
display navigation to standard display, buttons to callup custom displays.

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Main Live display features
Dynamic graphic objects color fills, conditional color change indicators

Bitmap import for static backgrounds and under dynamic program controls
Trend display with on line color change, cursor readout of point data.
User data entry fields and dialog box prompts.
Start, stop and switch to other windows.
MONITORING AND ALARMING OF INPUTS

INPUT PROCESSING
All inputs in maxDNA system have a unique 16 alphanumeric tag. Each tag has an associated
32 character descriptions.
Inputs for data acquisition are normally processed as Data Points, which are configured in
DPU. Each DPU processes Analog and Digital Inputs.
Each point in the database is classified and configured as a data point. Each input to be
monitored is assigned by configuration to a Data Point. The type is configured depending
upon the operation to be performed and the type of input.
Data points have the following configurable alarm settings
Low and High alarms
Significant change
Alarm based on reaching a value once or on repetitive basis
Return to normal alarm
Individual alarm cutout
Following Hardware Alarms are provided.
Open thermocouple
Instrument High
Instrument Low
Link fail
The status of raw input is provided for each of the above type of inputs. When any of these
alarms arise the data point value is no longer updated because these alarm indicate that no
better value are available.

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Quality
Every calculated variable and data point can have one of four quality coding descriptions:
Good, Bad, Doubtful and substitute. The code can be displayed on any operator station
graphic screen. These quality codes denote are explained below:
Bad The data source has an instrument alarm (link fail, open thermocouple,
instrument high, instrument low or a calculation is using bad value.
Substitute Operator entered value in manual mode or a calculation is using a
substituted value.
Doubtful Transformations using a bad value over part or full time period, data
point is in manual mode and its value is not being updated, or a calculation is using
doubtful value
Good None of the above
Data Reduction
Data points can perform comparisons, arithmetic calculations and similar data reduction
functions. All data point types perform comparisons, generally for alarm limits. They also
perform calculations, transforms and Boolean functions
Display Format
Data point displays contain value and an engineering unit with units of measure and a single
yellow bar representing percent of span. This bar is not necessarily zero based, but indicates
0% when the engineering unit value equals the RANGE LOW value and 100% when the
engineering unit value equals the RANGE HIGH value. Digital data points (contact closures)
are represented by a message or message pairs such as ON/OFF. Data points can appear in
any graphic in the system. Data points have a 12-character tag, a 12 character short title and
a 32 character long title.
Alarm Display
Alarms and events are received over the data highway from the DPUs where they are time
stamped. These include process alarms, operator actions and digital events. Upto 5000
alarms/events are maintained in the history buffer.
An Alarm summary display is provided which lists the latest 18 alarms. Paging backward will
reveal more alarms with the maximum number being 5000 active alarms. The latest five
alarms in an abbreviated form appear on the bottom right hand side of every graphic.

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The Alarms are displayed in chronological order. The newest alarm is on the top and the
oldest alarm is at the bottom of the alarm summary display. The background flashes for
unacknowledged alarms. Alarms are displayed in order of priority with the time indicated in
a different color designating the priority. There are 5 levels of priority.
Returns to normal alarms are also indicated. They are removed from the screen when
acknowledged by the operator. Alarms can also be printed.
REPORTS AND LOGS

Reports can be triggered by process events, manually by operator or can be scheduled for
example at the end of shift, day or month.
Process history can be represented in two ways, as summaries or as trends, the periods may
vary. Summary reports list data over an extended period. Typical standard periods include
an hour, a shift, a day, a week or a month. Trend reports list more detailed information
collected at relatively high resolution, such as one second interval during a 24 hour period.
Standard History Report package is provided as a part of HMI Software to create
professional looking printed reports containing historic trending data. Historic Trending data
consists of point attribute values, specified in the project.
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HMI in the maxDNA System can collect, store, and display trend history of any selected
attribute for analog or discrete points.
Data may be viewed in real time via maxVUE displays, can be archived in a maxSTATION, or
be printed in preformatted reports using the History Reports software.
The report software allows Configuration and scheduling of reports using any one of four
preformatted report types:
Trend
Summary
Trip
Shift
This software also allows definition of point groups, independent entities, containing point,
attribute statistics and algebraic expressions etc.

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The History Reports package consists of two major components, the Reports Editor and the
Reports Server. The Reports Editor component is used to configure the report in offline
mode. This component usually resides in a maxSTATION set up as an Engineer's workstation.
The Reports Server generates reports already configured in the Reports Editor.
The History Reports Package allows the various controls such as
Print reports on demand,
Preview reports before printing
Export, print, archive, or delete generated reports.
TREND REPORT
Of all the report types a trend report is the most basic, presenting trending data for
specified coverage periods. You may specify standard report coverage periods of an hour, a
shift, a day, a week, a month, or a year in addition to custom intervals.
SUMMARY REPORT
A Summary Report is similar to a trend report, but features summary rows to provide an
aggregate statistic at the end of each point column. The supported summary operations are
Average, Minimum, Maximum, Total, and No summary.

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TRIP REPORT
A trip report is generated in response to a specific event or combination of two events. An
event occurs when a state change is detected. A specified digital value may change from off
to on or false to true and vice-versa. In an actual situation, a device that was on may go to
an off state, triggering an event. This in turn, triggers a report.
When you specify scheduling based on two events, the second event (also based on a
specified digital value), must occur within a stated time period after the first event for a
report to be triggered. If the second event does not occur within the specified time, the first
event is ignored and no report is triggered.
The resulting report typically records the event, the name of the digital point triggering the
event and the state change, from on too off or off to on. The report shows similar
information for the second event, if the report is based on two-event scheduling.
The report shows events and sampling data before the event occurred and after. If the
report uses two events, it also shows samples for the period between the occurrences of
the two events.
You may specify a sampling period and sampling rate (row intervals) for a period before the
occurrence of the event and after.
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SHIFT REPORT
A shift report groups data by daily shift coverage periods, such as four hours, eight hours,
etc. The report may list data for one to four shifts within a 24-hour period. The report will
include hourly time intervals with a shift summary row and an aggregate statistic for
multiple shifts.

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Similar to a summary report, when you configure a shift report you may select from the
following supported summary operations: Average, Minimum, Maximum, Total, and No
summary.
Historical storage and archiving
The maxDNA system maintains and supports a historical storage and retrieval system
located in a maxSTATION, referred to as maxSTORIAN. Any maxSTORIAN instance can be
executed on a single, standalone maxSTATION.
The maxSTORIAN runs the long-term history system software and makes use of the disk
space in the maxSTATION.
Selected data from real time database is periodically stored at a fixed rate in the process
history buffer. It uses historic trending package is designed to collect and store trend data
for extended historic periods. The maxSTORIAN collects data using a delta-save style storage
and compression algorithm.
Using this approach, much more data may be retained and accessible online since not all
values are saved. Instead a delta from the last time the value changed is saved.
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On the History Storage display configuration, a sampling rate is configured in seconds, a

statistical rate in minutes or hours.
Permissible sampling rates for historical trending are:
1, 5, 30 seconds
Statistical data for storage is selectable for each analog point over the period selected.
Statistical points are collected at any one of the following rates:
1, 10 minutes, 1 hour
The data management software package enables the operators to use natural queries to
extract information. It is possible to sort data by time, date, points, area, functions, events
etc. The information is displayed in tabular format on the screen and can be printed as a log
on demand
HISTORICAL TRENDING
maxSTORIAN Trend allows the user to present historical data as a graphical trend on a CRT.
The package supports real time trending and historical trending. Users can change trending
tags, time spans of trends and resolution of trended data on-line. The flexibility of the
maxSTORIAN makes it a powerful process analysis tool in addition to being an easy-to-use
trending package. maxSTORIAN Trend is integrated together with maxDNA operators users
interface, maxVUE.
Up to eight values trended per monitor screen
Shading between points and to a fixed position in time
Add or change points or change ranges on-line
Users can create customized scales and trend borders
SEQUENCE OF EVENT RECORDING
Point configured for SOE will be recorded in two of the OWS (1&2) where Event
Recording server software is running. Point recording resolution will be 1 ms.
7. SYSTEM SCOPE
Scope of Supply
This section gives an overview of the equipments proposed for the Human Machine
Interface. These equipments are ideally configured to meet the plant requirements.

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The scope of supply of the HMI system hardware for the plant can be sub - divided into
following parts:
PC Compatible computer system.
Computer peripherals.
Network Components.
Included in the scope of supply is the internal power distribution between computer and the
peripherals as well as the cables for all data connections between the central computer and
the peripherals.

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HARDWARE COMPONENTS
1. maxSTATION comprising of the following:
Intel Core 2 Duo Processor running at 2.0 GHZ Frequency with 2 GB RAM. Operating
system used here is Windows XP
maxSTATION PC consists of the following main components:
Intel Xeon Processor, min 3 GHz

4 GB RAM
Hard disk drive, 320 GB
DVD ROM drive
Graphics I/F
Ethernet I/F (2 nos.)
ASCII keyboard
Optical Mouse
Serial port
USB Port
24 TFT Monitor
Windows XP Operating System (Licensed)
Additionally, engineer stations and maxSTORIAN stations will have a DVD WRITER.
2. Printers:
These are standard Dot Matrix printers for printing SOE and standard LaserJet
printers for printing alarms & logs.
3. Network components:
Ethernet switches and associated interfaces in PC and Remote Processing units and
interconnecting cables constitute network components.

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SOFTWARE COMPONENTS
SYSTEM SOFTWARE
System Software is an integrated package consisting of maxVUE, maxDPUTOOLS and
maxSTORIAN.
APPLICATION SOFTWARE
These are programs designed to execute along with the system software. These include
Process Database Configuration files, Plant Schematics and assignment of reports etc.
8. PROJECT ENGINEERING
Project Engineering consists of the following:
1. Creation of Database files.
Using maxDPUTOOLS, one configuration database file for each DPU is created and
function blocks are defined within the configuration representing an individual DPUs
associated I/O hardware, along with control and data acquisition processing. These
configuration files are downloaded to respective DPUs.
maxDPUTOOLS is a software utility that allows the engineer to create a configuration
database in offline mode. To configure points in an online environment, the maxVUE
Graphical Configurator, a separate software product available with the maxVUE
Editor software is to be used.
2. Creations of graphical Configurations
Using the Graphical Configuration tool, available through the maxVUE Editor, a point
database is represented graphically in the form of logic diagrams. Graphical
Configurator is used to create graphical representations of point databases, make
online edits to a configuration and document and print graphical representations of
configurations.
Logic diagrams appearing on sheets consist of a collection of boxes representing
atomic blocks [basic building blocks for example and, or, add etc] or elements of a
Custom Block [ex PID etc].
3. Creation of Graphics displays
Using maxVUE, the graphics displays are built which are used to view and control the
process. The maxVUE is used to create high-resolution, multi-colored process
graphics and trend presentations to control continuous or batch processes.
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The graphics displays are connected to the remote hardware devices. These graphics
displays model a given process and designate what is to be monitored or controlled.
Key processes in the plant such as generators, turbines, distributions etc are
represented in a number of displays.
The Editor is used interactively to create displays. Typical displays may represent
conditions or values, such as valve states and dam levels. Such displays may use
numerical data, and incorporate bar charts, trend graphs, and other MAXVUE
elements.
4. Configuring maxSTORIAN
The Configuration Editor available with maxSTORIAN is used to configure the points
to be collected by the maxSTORIAN instance
The Reports Package are used to retrieve data from the system over scheduled
intervals and to place this information on either a predefined formatted report or a
custom formatted report. Once created, the data used to create a report is saved in
a format allowing data to be extracted for use by Microsoft Access or custom
programs.
Reports Package is also used to archive the data saved for any generated report.


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HMI SYSTEM DESCRIPTION

3 X 660 MW PRAYAGRAJ STPP, BARA, UP

MAXDNA BASED HMI SYSTEM

BHEL DRG. NO.

EN DG 746 145 4001

Arjun Sundar Raj

Copyright and Confidential:

HMI SYSTEM DESCRIPTION

STANDARD APPLICATION SOFTWARE... 9

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HMI SYSTEM DESCRIPTION

HUMAN MACHINE INTERFACE

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HMI SYSTEM DESCRIPTION

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HMI SYSTEM DESCRIPTION

HMI provides the following functions:

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HMI SYSTEM DESCRIPTION

6. STANDARD APPLICATION SOFTWARE

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Displays are of various types like:

Point data pop-up

Point Detail pop-up

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System Status Display

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Network status Displays

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Horizontal & Vertical Toolbars

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Main Live display features

Dynamic graphic objects color fills, conditional color change indicators

MONITORING AND ALARMING OF INPUTS

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REPORTS AND LOGS

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On the History Storage display configuration, a sampling rate is configured in seconds, a

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