TECHNICAL REQUIREMENTS
Gas Pressure Regulator local/remote Controller
Development of software and hardware
Version 0.5 beta
Moscow 2014.
Contents
1.
Introduction ...................................................................................................................................... 3
2.
General Description........................................................................................................................... 3
3.
Power ................................................................................................................................................ 3
4.
I/O...................................................................................................................................................... 4
5.
Communications ............................................................................................................................... 4
6.
Performance ...................................................................................................................................... 5
7.
Features............................................................................................................................................. 5
8.
Operating Environment..................................................................................................................... 6
Appendix 1 ................................................................................................................................................ 7
Appendix 2 ................................................................................................................................................ 8
Appendix 3 ................................................................................................................................................ 9
Appendix 4 ..............................................................................................................................................10
2
1. Introduction
1.1. These technical requirements are designated to implement the software and hardware
complex (hereinafter referred to as controller) designed for local / remote control of a gas
pressure regulator. The gas pressure regulator must be equipped with a specialized system
that allows changing of the control pressure parameters (in the case of pneumatic
controllers) or controlling actuator (in the case of controllers equipped with electric
motors).
1.2. These technical requirements do not apply to the automated control system comprising
more than one controller (or one line regulation), for example, ACS GS, GRS, etc.
2. General Description
2.1. The controller is designed to perform the following basic tasks:
2.1.1. Maintaining the set point for the gas pressure regulator.
2.1.2. Remote set point adjustment of the gas pressure (by a command, an algorithm or a
schedule).
2.1.3. Maintaining a preset gas flow (in a certain range of minimum and maximum
pressure).
2.1.4. Controlling the heater (boiler) to maintain the desired gas temperature at the
regulator outlet, depending on the flow rate and pressure drop across the regulator.
There’s not connected to regulator’s control
At first this controller is not design to control also the preheating system
But we can think about this solution also. If we can implement a preheating-control, we also
have to control the boiler. But it is possible to use one of our standard 4-20mA outputs
(converted top 0-10V) to control a boiler-system also.
2.2. The controller is designed to work with the following types of regulators:
2.2.1. Gas pressure regulators with the pilot (electromagnetic stage);
2.2.2. Gas pressure regulators with the pilot (motorized stage);
Depends on Tormene system- first we have to know how pilots are organize
Yes you are right. But Tormene will have a motorized micro-controlvalve to manipulate the
pilot. In any case we will control all the valve-types via our 4-20mA outputs.
2.2.3. Gas pressure regulators with an electric motor;
2.3. The controller must ensure compatibility with the regulators of the following main
producers:
2.3.1. Tormene
2.3.2. RMG Regel
2.3.3. Others?
3. Power
3.1. Provide a power supply for both AC and DC inputs.
3.2. Parameters for AC input: 230V, 50Hz
3.3. Parameters for DC input: 24V
3.4. Provide overvoltage protection and over-current fuses to protect the controller.
3
3.5. Provide grounding of the controller through the appropriate terminals (in a power plug) and
an earth terminal on the body.
4. I/O
4.1. Digital inputs
4.1.1. The controller should have 16 digital inputs (minimum).
4.1.2. Digital inputs must be designed for 24 (48) V DC.
4.1.3. Provide for the possibility of expansion up to 32 digital inputs.
4.2. Digital outputs
4.2.1. The controller should have 16 digital outputs (minimum).
4.2.2. Digital outputs must be designed for 24 (48) V DC.
4.2.3. Provide for the possibility of expansion up to 32 digital outputs.
4.3. Analog inputs
4.3.1. The controller should have 8 analog inputs (minimum).
4.3.2. Analogue inputs must be designed for the range of 0 (4) ... 20 mA.
4.3.3. Provide for the possibility of expansion up to 12 analog inputs.
In general one 8-Canel-Card ore 2 4-Canel-Cards and an option to provide an additional 4Cannel-Card.
4.4. Analog outputs
4.4.1. The controller should have 4 analog outputs (minimum).
4.4.2. Analog outputs must be designed for a range of 0 (4) ... 20 mA.
4.4.3. Provide for the possibility of expansion up to 8 analog outputs.
In general one 4-Canel-Card and an option to provide an additional 4-Cannel-Card.
4.5. Frequency inputs
4.5.1. The controller should have 2 frequency inputs (minimum).
4.5.2. Frequency inputs must be designed for a range up to 5 kHz.
4.5.3. Provide for the possibility of expansion up to 4 frequency inputs.
4.5.4. The controller must count pulses received from the frequency conversion signal in
accordance with a preset weighting factor.
4.6. All the connections to the equipment located in the Ex area must be routed via barriers.
Depends on design if make decision for Exi we have to do that but better is to use Exe/d
filed devices without barriers
Yes you are right. If we have to provide Ex-I measurements we will place additional external
Ex-barriers or amplifier’s.
5. Communications
5.1. Provide the following interfaces for controller information transmission:
5.1.1. Ethernet (not less than 2 ports)
5.1.2. Speed of Ethernet – 100 Мбит/с
5.1.3. RS485 (not less than 2 ports)
5.1.4. Speed of RS485 - 115200 bps.
4
5.1.5. USB (not less than 2 ports)
5.2. Provide support for the following protocols:
5.2.1. ModBUS RTU
5.2.2. ModBUS TCP/IP
5.2.3. ProfiBUS/ProfiNET
5.2.4. CAN
5.3. Provide support for OPC s/w protocol.
5.4. Provide archiving and logging to a removable USB storage.
5.5. Provide software updates via USB or SD card replacement.
5.6. The controller shall integrate into automation systems of the main producers (Siemens etc.).
5.7. The controller shall provide integration into SCADA systems from major s/w companies
(Iconics etc.).
6. Performance
6.1. Performance of the controller should be sufficient to handle all the information from the
I/Os, as well as up to 8 PID control algorithms (with the possibility of PID chains and PID
control loops formation).
6.2. 6.2. Maximum cycle execution time (read data from inputs - processing - recording
parameters to outputs) should not exceed 100 ms.
We should have an IEC 61131 compiler like CoDeSys ore PLCopen, the HW should provide
programmcode for more than 8 control-loops and should be able to perform that in min 100mscycle
7. Features
7.1. The controller must be equipped with the LCD screen.
7.1.1. LCD screen (HMI) is located in front of the controller.
7.1.2. Minimum screen size is 5.7 ".
7.1.3. Minimum screen resolution is 640×480 (VGA). Better is HD
7.1.4. Function keys (6 to 12 keys) should be located adjacent to the screen.
7.1.5. Function keys should be a membrane type.
7.1.6. One USB and one RJ45 connector should be placed on the front side.
7.1.7. LCD screen (HMI) should be touchscreen.
7.2. The housing must meet the following criteria:
7.2.1. Height: 3U Pay attention what kind
7.2.2. Width: ½ 19”
Possibility of 19” rack mounting and/or on door elevation point 8.1
3U and ½ 19” is in mm W 234 mm / H 134 mm. This should be big enough to provide a display
up to 7”. The RMG Flow-Computer have the same size. The Foto at the first page shows the
EM302-Conbtroler it is exact this size and it woks with a 5,7” Display. I’m with you, we shold
have a better display.
5
7.3. Removable media should be provided to store the controller internal information.
7.3.1. A memory card must be provided for the local info storage and system files. SD card
can be used for this purpose.
7.3.2. It should be possible to use an USB Flash Driver for the controller information
storage and transfer.
7.4. I/O connectors are located at the rear of the controller.
7.4.1. Jumper cables can be used for quick I/O wiring up.
8. Operating Environment
8.1. The controller is designed for installation in industrial electrical cabinets and racks.
8.2. The controller can be operated at a temperature range from 0 to +45˚С.
8.3. Condensation of moisture on the body and parts of the controller during its operation is not
allowed.
8.4. The controller protection standard should be IP20 (minimum).
The Controldevice has to have a protection standard of IP30 ore better. The HMI-Front of this
Device has to have protection standard of IP44 ore better”.
6
Appendix 1
Block diagram of the system for the pilot stage regulators with electromagnetic.
7
Appendix 2
List of signals for system controllers with electromagnetic stage.
№
1
2
3
4
5
6
7
8
9
10
11
12
13
14
15
16
17
18
19
20
21
22
23
24
25
26
27
28
29
30
31
Name
Inlet valve is open
Inlet valve is closed
Inlet valve, torque, left
Inlet valve, torque, right
Inlet valve, thermal protection
Outlet valve is open
Outlet valve is closed
Outlet valve, torque, left
Outlet valve, torque, right
Outlet valve, thermal protection
SSV №1 is closed
SSV №2 is closed
SRV №1 is open
SSV №2 is open
"Close" inlet valve
«Open» inlet valve
Mode of operation of the inlet valve
"Close" outlet valve
«Open» outlet valve
Mode of operation of the outlet valve
The inlet gas pressure, MPa
The outlet gas pressure, MPa
The gas pressure at the meter, MPa
The gas temperature at the meter, °С
Gas flow, m3/h
Gas flow standart, m3/h
The degree of opening of the regulator,%
The control action
Bypass valve open
Accident regulator
System Failure
Total
Discrete
DI
+
+
+
+
+
+
+
+
+
+
+
+
+
+
+
+
++
+
+
++
DO
+
+
Analog
AI
+
+
+
+
+
+
+
+
+
+
+
+
+
+
+
+
+
22
Digital
AO
+
+
+
15
7
+
+
+
+
4
8
Appendix 3
Block diagram of the system for regulators with electric motor.
9
Appendix 4
List of signals for system controls an electric motor.
№
1
2
3
4
5
6
7
8
9
10
11
12
13
14
15
16
17
18
19
20
21
22
23
24
25
26
27
28
29
30
31
Name
Inlet valve is open
Inlet valve is closed
Inlet valve, torque, left
Inlet valve, torque, right
Inlet valve, thermal protection
Outlet valve is open
Outlet valve is closed
Outlet valve, torque, left
Outlet valve, torque, right
Outlet valve, thermal protection
SSV №1 is closed
SSV №2 is closed
SRV №1 is open
SSV №2 is open
"Close" inlet valve
«Open» inlet valve
Mode of operation of the inlet valve
"Close" outlet valve
«Open» outlet valve
Mode of operation of the outlet valve
The inlet gas pressure, MPa
The outlet gas pressure, MPa
The gas pressure at the meter, MPa
The gas temperature at the meter, °С
Gas flow, m3/h
Gas flow standart, m3/h
The degree of opening of the regulator,%
The control action
Bypass valve open
Accident regulator
System Failure
Total
Discrete
DI
+
+
+
+
+
+
+
+
+
+
+
+
+
+
+
+
++
+
+
++
DO
+
+
Analog
AI
+
+
+
+
+
+
+
+
+
+
+
+
+
+
+
+
+
22
Digital
AO
+
+
+
15
7
+
+
+
+
4
10