Regul Rx00 Programmable Logic Controllers

REGUL RX00 PROGRAMMABLE LOGIC CONTROLLERS

2019 automation.gp-systems.com Contents

REGUL RX00 Programmable Logic Controllers 2 REGUL R600 Programmable Logic Controller 2 Hardware Configuration 6 Smart I/O Modules 7 Redundancy 8 Dimensional Drawings 9 REGUL R500 Programmable Logic Controller 10 Examples of Rack Connections 15 Smart I/O Modules 16 Redundancy 17 Dimensional Drawings 18 REGUL R400 HMI / Programmable Logic Controller 20 Hardware Configuration 21 Dimensional Drawings 21 REGUL R200 Programmable Logic Controller 22 Hardware Configuration 25 Dimensional Drawings 26 EPSILON LD – IEC 61131-3 Programming and Configuration Software for REGUL Controllers 28

Industrial Solutions and Examples 30 Oil and Gas 30 Fiscal Metering – Control System for Lease Automatic Custody Transfer (LACT) Units 30 Control System for Oil Pumping Stations 32 Control System for Gas Pressure Regulators 34 Fire and Gas System 36 Telemetry Solution 39 Gas Odorizing Control System 40 Power Generation and Distribution 41 Thyone - Protection and Control System for Steam and Gas Turbines 41 Tarvus – Electronic Overspeed Trip for Steam and Gas Turbines 42 Automatic Load-Frequency Control System 43 Turbo-generator Vibration Monitoring System 45 MS5002E (Mark VIe) Gas Turbine Control System 46 Other 47 Industrial Converter Gateway 47

1 REGUL R600 Programmable Logic Controller

Regul R600 is a high-availability real-time programmable logic controller, designed for the use in process industries, where additional electromagnetic protection, vandal-proof housing, and/or extended temperature range are preferred.

Applications • High-availability process control systems for • Steam and gas turbines (control and emergency protection) • Oil pumping stations and gas compressors • Main and auxiliary systems at power stations • Fire and gas systems • Water management systems • Fiscal applications (for example, LACT units) • Applications with unstable connection to upper level • Applications with large number of tags sent to upper level

Redundancy • Hot swapping of all modules • Hot-standby CPU modules • Dual ring high-speed internal data bus • Automatic power distribution between power supply modules • Redundancy of CPU, CPU interconnection, I/O modules, power supply modules, SCADA connection • Hybrid counter/digital modules with support of 2oo3 voting at the level of modules

General Features • Real-time programmable logic controller • Modular configuration, allowing flexible extension and change of configuration • Supports up to 130,000 channels • Improved electromagnetic protection of the controller and enclosure of the modules, protective module form factor • In-module event archiving Processing power and redundancy • Minimum application cycle time – 1 ms (5 ms with redundancy) • Scan time – 1 ms • Switchover in 5 ms • Processing of complex algorithms with powerful CPU modules and built-in microprocessors in I/O modules System configuration • Up to 12 modules in a rack, up to 255 racks, up to 10 km (via fiberoptic line) between racks • RJ-45, SFP, or mixed connection between racks • Star, ring, or mixed network topologies • CPU module can be placed into any rack Programming and visualization • Programming in Epsilon LD software with IEC 61131-3 languages + CFC • Online application update • Remote configuration/maintenance and application updates • Special firmware with MySQL database server • CPU module with DVI output for connecting a display and using Target-visualization • Web visualization option in CPU modules

2 automation.gp-systems.com

Supported interfaces Communications • RS-232 (9-pin, full duplex, speed 300–115, 200 bps, opto-isolation 500/1500 V, overvoltage protection) • RS-422/RS-485 (9-pin, speed 300–115, 200 bps, full-channel opto-isolation 500/1500 V, overvoltage protection) – up to 96 ports per controller • Ethernet 10/100/1000 RJ-45 (full duplex) – up to 4 ports per CPU • Ethernet 10/100/1000 fiberoptic (single-mode, multi-mode) – up to 2 ports per CPU Built-in communication protocols* • IEC 61870-5-101 (master/slave) • IEC 61870-5-104 (master/slave) • Modbus RTU (master/slave, with expansion capabilities) • Modbus TCP (master/slave, with expansion capabilities) • OPC DA, OPC UA • EtherCAT *Additional communication protocols, including non-standard ones, can be implemented according to your requirements.

• Eurocard-size I/O modules: 30×267×186 mm (W×H×D) Design • 19” rack mount • On-panel or in-cabinet mounting • Detachable terminal blocks • Passive cooling; no mechanical or rotating structural components

Specifications Minimum application cycle time 1 ms (5 ms in redundant configuration) Scan time 1 ms Switchover time from main to standby controller 5 ms Timing accuracy 50 µs Processor Intel Atom RAM 1 Gb SSD 4 Gb (optional up to 64 Gb) Mean time between failures (MTBF) >150,000 hours for a controller module Input power 85…264 VAC 18…36 VDC 120…370 VDC I/O module size (W x H x D) 30 х 267 х 186 mm Operating temperature range -40…+60°С Approvals CE, EAC, GOST-R, FCC-ready

March, 2019 March, 3 Channels Part number Description (ports) CPU MODULES Central processor unit module • Redundancy support • Intel Atom • 1 × 2 GB RAM, 1 × 4 GB Flash • 1 × RS-232, 1 × RS-485, CU 00 052 • 4 × Ethernet RJ-45 • 2 × USB host • GPS/GLONASS receiver CU 00 052 (W) additionally includes web server with support of Web visualization

Central processor unit module • Redundancy support • Intel Atom • 1 × 2 GB RAM, 1 × 4 GB Flash • 1 × RS-232, 1 × RS-485, CU 00 062 • 2 × Ethernet RJ-45, 2 × Ethernet SFP • 2 × USB host • GPS/GLONASS receiver CU 00 062 (W) additionally includes web server with support of Web visualization

Central processor unit module • Redundancy support • Intel Atom • 1 × 2 GB RAM, 1 × 4 GB Flash • 1 × RS-232, 1 × RS-485, CU 00 072 • 2 × Ethernet RJ-45, 2 × Ethernet SFP • 2 × USB host, 1 × DVI • GPS/GLONASS receiver CU 00 072 (W) additionally includes web server with support of Web visualization POWER SUPPLY Power supply module 24 V DC, 75 W AND BUS EXTENSION PP 14 011 • Redundancy support MODULES • Bus extension ports (IN, OUT), RJ-45 Power supply module 24 V DC, 75 W PP 14 021 • Redundancy support • Bus extension ports (IN, OUT), SFP Power supply module 220 V AC/DC, 75 PP 14 031 • Redundancy support • Bus extension ports (IN, OUT), RJ-45 Power supply module 220 V AC/DC, 75 W PP 14 041 • Redundancy support • Bus extension ports (IN, OUT), SFP

COMMUNICATION Communication processor RS-485 (Modbus RTU, IEC-61870-5- CP 04 011 4 MODULES 101, user protocols), 4 ports

I/O MODULES Analog input, AI module (current) • Current measuring range: 0…20 mA, 4…20 mA • 16 channels AI 16 011 16 • Resolution: 14 bits (including overflow) • Operating error under normal conditions: ±0.1% • Common galvanic isolation Analog input, AI module (current, HART) • Current measuring range: 0…20 mA, 4…20 mA • 8 channels • Resolution: 16 bits (including overflow) AI 08 021 8 • Operating error under normal conditions: ± 0.1% • Built-in HART protocol • 1 ADC and 1 HART-modem for each channel • Channel galvanic isolation

4 automation.gp-systems.com

Analog input, AI module (thermal resistances, thermocouples) • Thermal resistance measurement range: 1…450 Ohm • 8 channels • Supported thermal resistances: Cu50, Cu100, Pt50, Pt100, AI 08 031 Ni50, Ni100 8 • Supported thermocouples: R, S, B, J, T, E, K, N, A-1, A-2, A-3, L • Resolution: 24 bits (including overflow) • Operating error under normal conditions: ±0.1% • Common galvanic isolation Analog input, AI module (current, voltage; high-accuracy) • Current measuring range: 0…20 mA, 4…20 mA • 8 channels • Voltage measuring range: 0…+10 V, -10…+10 V AI 08 041 8 • Resolution: 16 bits (including overflow) • Operating error under normal conditions: ±0.025% • Channel galvanic isolation • Individual ADC for each channel Analog output, AO module (current) • Output range, current: 0…20 mA, 4…20 mA • 8 channels AO 08 011 8 • Resolution: 16 bits • Operating error under normal conditions: ±0.1% • Channel galvanic isolation Analog output, AO module (current, HART) • Output range, current: 0…20 mA, 4…20 mA • 8 channels AO 08 021 8 • Operating error under normal conditions: ±0.1% • Built-in HART protocol • Channel galvanic isolation Digital input, DI module • Input current: 24 VDC DI 32 011 32 • 32 channels (4 groups by 8 channels) • Group galvanic isolation Digital output, DO module • Output current: 24 VDC / 0.5 A DO 32 011 32 • 32 channels (4 groups by 8 channels) • Group galvanic isolation Counter/digital module • Channel supply voltage: 3, 5, 12, 24 V • Frequency measurement range: 1 Hz … 500 kHz • Frequency generation range: 1 Hz … 10 kHz • Pulse measurement range: 1…264 (with overflow) • Operating error under normal conditions, frequency: less than DA 03 011 ± 0.01% 3/1/6/6 • Pulse-counting error: ±1 pulse • 3 × counter channels • 1 × generator channel • 6 × DI channels, 24 V • 6 × DO channels, 24 V / 0.5 A • Channel galvanic isolation of the counter channels Counter/digital module • Channel supply voltage: 5, 12, 24 V • Frequency measurement range: 1 Hz … 500 kHz • Frequency generation range: 1 Hz … 10 kHz • Pulse measurement range: 1…264 (with overflow) • Operating error under normal conditions, frequency: less than ± 0.01% DA 03 022 • Pulse-counting error: ±1 pulse 3/1/6/6 • 3 × counter channels • 1 × generator channel • 6 × DI channels, 24 V • 6 × DO channels, 24 V / 0.5 A • Built-in software for electronic overspeed trip • Support of magnetic RPM sensor • Channel galvanic isolation of the counter channels

5 CHASSIS CH 07 011 Chassis with 7 slots (1 PP and 5 expansion slots) - CH 14 011 Chassis with 14 slots (1 PP and 12 expansion slots) -

OTHER OO 00 000 Empty module (slot cover) -

DB 37 020 Cable with one DSUB-37 connector (male), length 2 m -

PCL-10137-2E Cable with two DSUB-37 connectors (male), length 2 m -

Hardware Configuration

• Up to 255 expansion racks • Up to 12 input/output modules in one rack (single-channel option) • Support of redundant internal network by I/O modules

Central Processor Create

Holder

Imput data processing CPU CPU MCU MCU MCU MCU and diagnostic s

centra l centra l imput/output communicatio n imput/output imput/output processo r processo r module processo r module module Power unit modul e

Power unit modul e modul e modul e modul e

MCU MCU MCU MCU MCU MCU

imput/output imput/output imput/output imput/output imput/output communicatio n processo r module module Power unit modul e Power unit modul e module module module modul e

Backup ring

6 automation.gp-systems.com Smart I/O Modules

Each input/output module in the REGUL R600 series holds two independent ports for communicating with CPU modules over Regul bus. This allows information to be delivered from modules simultaneously to active and standby CPU and provide instant switchover.

The primary processing of a signal Input/output modules provide for: is performed in the module and includes: • Support for the redundant bus communication • Signal diagnostics for range overshooting • Maximum delay for generating an output and abrupt value changes signal when the input set point (input-output) • De-jittering function for digital signals is triggered: 5 ms • Programmable averaging time • Galvanic isolation between the internal and external • Signal conversion values in engineering units circuits up to 1000 V • Monitoring for a short-circuit or open input circuit • Assignment of a timestamp with an accuracy of 1 ms of analog signals • Transmission of diagnostic data and different statuses • Monitoring for an open output circuit of analog signals • Configuration of output presets

Redundancy Redundancy parameters: Conditions to transfer control: • Switchover time: less than 5 ms • Based on the results of PLC bus diagnostics • Redundant data transmission protocol: UDP • Operator stopping the application • Duplicated communication channels between • Occurs in the absence of communication with the processors master CPU • Automatic synchronization of the application program

7 REGUL R600 Redundancy Schemes

100% Mirror Redundancy CPU and Power Redundancy

Combined redundancy

8 automation.gp-systems.com Dimensional Drawings

210 267

9 REGUL R500 Programmable Logic Controller

Regul R500 is a high-availability real-time programmable logic controller, designed for the use in process industries. It features high-speed dual ring data bus, allowing fast collection of data for further processing, even with complex algorithms, without compromising on speed. Its flexibility of communications and a special focus on redundancy, instrument-free replacement of hot-swappable modules, make it controller of choice when processes must go uninterrupted.

Redundancy • Hot swapping of all modules • Hot-standby CPU modules • Dual ring high-speed internal data bus • Automatic power distribution between power supply modules • Redundancy of internal bus, CPU, CPU interconnection, I/O modules, power supply modules, SCADA connection • Hybrid counter/digital modules with support of 2oo3 voting at the level of modules

General Features • Real-time programmable logic controller • Modular configuration, allowing flexible extension and change of configuration • Supports up to 130,000 channels • In-module event archiving Processing power and redundancy • Minimum application cycle time – 1 ms (5 ms with redundancy) • Scan time – 1 ms • Switchover in 5 ms • Processing of complex algorithms with powerful CPU modules and built-in microprocessors in I/O modules System configuration • Up to 40 modules in a rack, up to 255 racks, up to 10 km (via fiberoptic line) between racks • RJ-45, SFP, or mixed connection between racks • Star, ring, or mixed network topologies • CPU module can be placed into any rack Programming and visualization • Programming with IEC 61131-3 languages + CFC in Epsilon LD software • Online application update • Remote configuration/maintenance and application updates • Special firmware with MySQL database server • CPU module with DVI output for connecting a display and using Target-visualization • Web visualization option in CPU modules

10 automation.gp-systems.com

Supported interfaces Communications • RS-232 (9-pin, full duplex, speed 300–115, 200 bps, opto-isolation 500/1500 V, over voltage protection) • RS-422/RS-485 (9-pin, speed 300–115, 200 bps, full-channel opto-isolation 500/1500 V, overvoltage protection): up to 96 ports per controller • Ethernet 10/100/1000 RJ-45 (full duplex): up to 4 ports per CPU • Ethernet 10/100/1000 fiberoptic (single-mode, multi-mode): up to 2 ports per CPU Built-in communication protocols* • IEC 61870-5-101 (master/slave) • IEC 61870-5-104 (master/slave) • Modbus RTU (master/slave, with expansion capabilities) • Modbus TCP (master/slave, with expansion capabilities) • OPC DA, OPC UA • EtherCAT *Additional communication protocols, including non-standard ones, can be implemented according to your requirements.

• Mid-size dimensions: 40×180×145 mm (W×H×D) Design • Detachable terminal blocks • Installation on a 105-mm DIN rail, with a clamp • Passive cooling; no mechanical or rotating structural components

Specifications Minimum application cycle time 1 ms (5 ms in redundant configuration) Scan time 1 ms Switchover time from main to standby controller 5 ms Timing accuracy 50 µs Processor Intel Atom, ARM Cortex-Axx RAM 2 GB, 512 MB Flash memory (CU 00 021, 031) 1 GB SSD (CU 00 051, 061, 071) 4 GB (optional up to 64 GB) Input power 85…264 VAC 18…36 VDC 120…370 VDC I/O module size (W x H x D) 40 × 180 × 145 mm Operating temperature range 0…+60°С Approvals CE, EAC, GOST-R, FCC-ready

11 Channels Part number Description (ports) CPU MODULES Central processor unit module • Redundancy support • Intel Atom • 1 × 2 GB RAM, 1 × 4 GB SSD • 1 × RS-232, 1 × RS-485, CU 00 051 • 4 × Ethernet RJ-45 - • 2 × USB host • GPS/GLONASS receiver

CU 00 051 (W) additionally includes web server with support of Web visualization Central processor unit module • Redundancy support • Intel Atom • 1 × 2 GB RAM, 1 × 4 GB SSD • 1 × RS-232, 1 × RS-485, CU 00 061 • 2 × Ethernet RJ-45, 2 × Ethernet SFP - • 2 × USB host • GPS/GLONASS receiver

CU 00 061 (W) additionally includes web server with support of Web visualization Central processor unit module • Redundancy support • Intel Atom • 1 × 2 GB RAM, 1 × 4 GB SSD • 1 × RS-232, 1 × RS-485, CU 00 071 • 2 × Ethernet RJ-45, 2 × Ethernet SFP - • 2 × USB host, 1 × DVI • GPS/GLONASS receiver

CU 00 071 (W) additionally includes web server with support of Web visualization

PP 00 011 24 VDC, 75 W power supply module, without galvanic isolation -

PP 00 021 24 VDC, 75 W power supply module, with galvanic isolation -

PP 00 031 220 VAC/VDC, 75 W power supply module, with galvanic isolation -

COMMUNICATION MODULES CP 04 011 Communication processor RS-485 (Modbus RTU), 4 ports 4

CP 02 021 Communication processor Ethernet (Modbus TCP), 2 ports 2

Communication processor for Regul bus segments, EtherCAT, RJ- CP 06 111 6 45, 6 ports I/O MODULES Analog input, AI module (current) • Current measuring range: 0…20 mA, 4…20 mA • 16 channels AI 16 011 • Resolution: 14 bits (including overflow) 16 • Operating error under normal conditions: ±0.1% • Shared ADC for all channels • Common galvanic isolation Analog input, AI module (current, HART) • Current measuring range: 4…20 mA • 16 channels • Resolution: 16 bits (including overflow) AI 16 081 • Operating error under normal conditions: ± 0.1% 16 • Built-in HART protocol • 1 ADC and 1 HART-modem per channel group (2 groups of 8 channels) • Group galvanic isolation

12 automation.gp-systems.com

Analog input, AI module (current, HART) • Current measuring range: 0…20 mA, 4…20 mA • 8 channels AI 08 021 8 • Operating error under normal conditions: ± 0.1% • Built-in HART protocol and HART modem • Channel galvanic isolation

Analog input, AI module (thermal resistances, thermocouples) • Thermal resistance measurement range: 20…400 Ohm • 8 channels • Supported thermal resistances: Cu50, Cu100, Pt50, AI 08 031 8 Pt100, Ni50, Ni100 • Supported thermocouples: R, S, B, J, T, E, K, N, A-1, A-2, A-3, L • Operating error under normal conditions: ±0.1% • Common galvanic isolation

Analog input, AI module (current, voltage; high-accuracy) • Current measuring range: 0…20 mA, 4…20 mA • Voltage measuring range: 0…+10 V, -10…+10 V • 8 channels AI 08 041 8 • Resolution: 14 bits (including overflow) • Operating error under normal conditions: ±0.025% • Channel galvanic isolation • Individual ADC for each channel

Analog input, AI module (current, voltage) • Current measuring range: 0…20 mA, 4…20 mA • Voltage measuring range: 0…+10 V, -10…+10 V • 8 channels AI 08 051 8 • Resolution: 14 bits (including overflow) • Operating error under normal conditions: ±0.1% • Channel galvanic isolation • Shared ADC for all channels

• Analog output module (current) • Output range, current: 0…20 mA, 4…20 mA • 8 channels AO 08 011 8 • Resolution: 16 bits • Operating error under normal conditions: ±0.1% • Channel galvanic isolation Analog output module (current, HART) • Output range, current: 0…20 mA, 4…20 mA (HART) • 8 channels AO 08 021 • Resolution: 16 bits 8 • Built-in HART protocol and HART modem • Operating error under normal conditions: ±0.1% • Channel galvanic isolation Analog output module (current, voltage) • Output range, current: 0...20 mA, 4…20 mA • Output range, voltage: 0…+10 V, -10…+10 V AO 08 031 • 8 channels 8 • Resolution: 16 bits • Operating error under normal conditions: ±0.1% • Channel galvanic isolation

Hybrid analog module (current, voltage) • Current measuring range / output current: 0…20 mA, 4…20 mA • Voltage measuring range / output voltage: 0…+10 V, -10…+10 V 6 (input) / • 6 × AI channels, shared ADC for all channels AS 08 011 2 (output) • 2 × AO channels, individual ADC for each channel • Resolution: 14 bits (including overflow) • Operating error under normal conditions: ±0.1% • Channel galvanic isolation

Digital input, DI module • Input current: 24 VDC DI 32 011 32 • 32 channels (4 groups by 8 channels) • Group galvanic isolation

13 Digital input, DI module • Input current: 24 VDC DI 32 111 • 32 channels (4 groups by 8 channels) 32 • Galvanic isolation with bus and power supply – 1,500 V • Group galvanic isolation

Digital input, DI module • Input current: 220 VAC/VDC DI 16 021 16 • 16 channels • Channel galvanic isolation

Digital output, DO module • Output current: 24 VDC / 0.5 A DO 32 011 32 • 32 channels (4 groups by 8 channels) • Group galvanic isolation

Digital output, DO module • Output current: 220 VAC / 2 А, 220 VDC / 0.3 A DO 16 021 16 • 16 channels • Channel galvanic isolation

Hybrid digital module 24 (input) / • 24 × DI (3 groups by 8 channels), 24 VDC DS 32 011 8 (output) • 8 × DO, 24 VDC/0.5 A • Group galvanic isolation Counter/digital module • Channel supply voltage: 4…24 V • Frequency measurement ranges: 1…10 kHz (enhanced accuracy), 1…500 kHz • Pulse measurement range: from 1…264 (with overflow) • Operating error under normal conditions, frequency: DA 03 011 3/6/6 less than ± 0.01% • Pulse-counting error: ±1 pulse • 3 × counter channels • 6 × DI channels, 24 V • 6 × DO channels, 24 V / 0.5 A • Channel galvanic isolation of the counter channels Counter/digital module • Channel supply voltage: 5, 12, 24 V • Frequency measurement range: 1 Hz…500 kHz • Pulse measurement range: 1…264 (with overflow) • Operating error under normal conditions, frequency: less than ± 0.01% DA 03 021 • Pulse-counting error: ±1 pulse 3/1/6/6 • 3 × counter channels • 1 × generator channel • 6 × DI channels, 24 V • 6 × DO channels, 24 V / 0.5 A • Channel galvanic isolation of the counter channels • Electronic overspeed trip software

BUS MODULES ST 00 001 Termination module without bus extension function -

ST 01 011 Bus extension module (IN), RJ-45, non-redundant bus 1

ST 01 021 Bus extension module (OUT), RJ-45, non-redundant bus 1

ST 02 011 Bus extension module (IN), RJ-45, redundant bus 2

ST 02 021 Bus extension module (OUT), RJ-45, redundant bus 2

ST 02 111 Bus extension module (IN), SFP, redundant bus 2

ST 02 121 Bus extension module (OUT), SFP, redundant bus 2

14 automation.gp-systems.com Examples of Rack Connections

• Support of a redundant CPU module installed in the same rack or in another rack • Connection of up to 255 expansion racks • Up to 40 modules in one rack • Maximum distance between racks of 10 km (via fiber-optic line)

In one system you can combine REGUL controllers from several series. For example, have R500 CPU racks and I/O racks made of R200 racks and R500 racks.

15 Smart I/O Modules

Each input/output module in the REGUL R500 series holds two independent ports for communicating with CPU modules over Regul bus. This allows information to be delivered from modules simultaneously to active and standby CPU and provide instant switchover.

The primary processing of a signal Input/output modules provide for: is performed in the module and includes: • Support for the redundant bus communication • Signal diagnostics for range overshooting • Maximum delay for generating an output signal and abrupt value changes when the input set point (input-output) is trigge- • De-jittering function for digital signals red: 5 ms • Programmable averaging time • Galvanic isolation between the internal • Signal conversion values in engineering units and external circuits up to 1000 V • Monitoring for a short-circuit or open input • Assignment of timestamps with an accuracy circuit of analog signals of 1 ms • Monitoring for an open output circuit of analog • Transmission of diagnostic data and different signals statuses • Configuration of output presets

Redundancy Redundancy parameters: Conditions to transfer control: • Switchover time: less than 5 ms • Based on the results of PLC bus diagnostics • Redundant data transmission protocol: UDP • Operator stopping application • Duplicated communication channels between • Occurs in the absence of communication with processors the master CPU • Automatic synchronization of the application program

16 automation.gp-systems.com REGUL R500 Redundancy Schemes

100% Mirror Redundancy

Shared I/Os, redundant bus, CPUs, CPU interconnection

100% CPU redundancy, shared I/Os

17 Dimensional Drawings

100% CPU redundancy, shared I/Os

40 180

47 155,0

CPU Modules 40 180 180

145

155 80 47 155,0

18 automation.gp-systems.com

Bus Extension Modules, RJ-45 130

40 44,5

Bus Extension Modules, SFP 130

40 70

19 REGUL R400 HMI / Programmable Logic Controller

The REGUL R400 controller is a combination of a hu- man - machine interface (HMI) and a CPU in one module. Internally it shares most of the electronic part with R500 CU 071 CPU module. Internal bus supports ring operation and the device can operate in one system with I/O module of any other REGUL series.

Applications Standalone and distributed automation systems with visualization

Features • Display of visualization created in Epsilon LD • Internal SSD for user archives • Operates as a CPU module for REGUL R600, R500, R200 I/O modules • Supports up to 255 expansion racks • Extended temperature range • Programming with five IEC 61131-3 languages in Epsilon LD softwares

• 7” touchscreen display Design • IP66 ingress protection for the front panel • Steel housing • Rack- or door-mount • Membrane keyboard

Specifications Display size 7” Display resolution 800 × 480 Colors 16.7 M Touchscreen type Capacitive Processor type Intel Atom Processor speed 1.46 GHz RAM 2 Gb SSD 4 Gb Interfaces 1 × RS-485 2 × USB host 2 × Ethernet RJ-45 2 × Regul bus (IN, OUT) Input power 85…264 VAC 18…36 VDC 120…370 VDC Operating temperature range 18…36 VDC Approvals -20…+40 oC Approvals CE, EAC, GOST-R

20 automation.gp-systems.com Hardware Configuration

• Supports up to 255 expansion racks • Additional racks could be connected via star or ring topology

REGUL R400

REGUL R500

REGUL R200

Hardware Configuration

236 47 169 139

206 51,2 42

Dimensions of the panel’s cutout for mounting the R400: W×H = 210±2 × 145±2 mm.

21 REGUL R200 Programmable Logic Controller

REGUL R200 was designed to operate as a standalone compact system or a remote I/O. This series features powerful CPU modules with RS- 232, RS-485, RJ-45/SFP ports, has built-in communication protocols (OPC UA/DA, Modbus TCP/RTU), hold GPS/Glonass receiver for built- in time server, and have MMC slots for additional/removable memory. The major advantage of REGUL R200 is its size, allowing its installation in the limited space. Support of Regul bus allows its operation in the systems with other REGUL controllers, with all the system programmable with the same software, Epsilon LD

Applications • Remote I/O in oil and gas • Telemetry systems • Gas odorizing, gas heating systems • Utilities • Plastic manufacturing • Other small- and medium-sized systems and as remote I/Os for Regul R500/R600

Features • Hot-swapping of all controller modules • Modular configuration, allowing flexible extension and change of configuration • Up to 70 modules in one rack • Interoperability with other REGUL PLCs on the shared bus or added bus segment • Extended temperature range • Programming with five IEC 61131-3 languages + CFC, in Epsilon LD software

Supported interfaces Communications • • RS-232 (9-pin, full duplex, speed 300–115, 200 bps, opto-isolation 500/1500 V, overvoltage • protection) • • RS-422/RS-485 (9-pin, speed 300–115, 200 bps, full-channel opto-isolation 500/1500 V, • overvoltage protection): up to 96 ports per controller • • Ethernet 10/100/1000 RJ-45 (full duplex): up to 2 ports per CPU • • Ethernet 10/100/1000 FO (single-mode, multi-mode): up to 1 port per CPU Built-in communication protocols* • IEC 61870-5-101 (master/slave) • Modbus RTU (master/slave, with expansion capabilities) • Modbus TCP (master/slave, with expansion capabilities)

Design • Compact dimensions, 15 x 101 x 104 mm (W×H×D) • Convenient chassis—replace modules without disconnecting cables • Passive cooling; no mechanical or rotating components • Installation on a 35-mm DIN rail • Possibility of using locking and sealing elements for fiscal applications • Location coding according to the module type

Specifications Minimum application cycle time 1 ms Timing accuracy 50 µs (CU 00 041, CU 00 061) Processor type ARM Cortex Axx RAM 512 Mb Flash memory 1 Gb Input power 18…36 VDC I/O module size (W x H x D) 15 x 101 x 104 mm Operating temperature range -40…+60 oC Approvals CE, EAC, GOST-R, FCC-ready

22 automation.gp-systems.com

Channels Part number Description (ports) CPU MODULES CPU module, standalone operation, no Regul bus support • ARM Cortex-Axx CU 00 021 • 1 × 512 MB RAM, 1 × 1 GB Flash - • 1 × RS-232, 1 × RS-485 • 1 × Ethernet RJ-45 Includes one R200 PP 00 011 power supply module

CPU module, expansion racks via star topology • ARM Cortex-Axx • 1 × 512 MB RAM, 1 × 1 GB Flash CU 00 031 • 1 × RS-232, 1 × RS-485 - • 1 × Regul bus • 1 × Ethernet RJ-45 Includes one R200 PP 00 011 power supply module

CPU module, expansion racks via star or ring topology • ARM Cortex-Axx • 1 × 512 MB RAM, 1 × 1 GB Flash CU 00 041 • 1 × RS-232, 1×RS-485 - • 2 × Regul bus (IN, OUT) • 2 × Ethernet RJ-45 • GPS/Glonass receiver Includes one R200 PP 00 011 power supply module

CPU module, expansion racks via star or ring topology • ARM Cortex-Axx • 1 × 512 MB RAM, 1 × 1 GB Flash CU 00 061 • 1 × RS-232, 1 × RS-485 - • 2 × Regul bus (IN, OUT) • 1 × Ethernet RJ-45, 1 × Ethernet SFP • GPS/Glonass receiver Includes one R200 PP 00 011 power supply module

PP 00 011 Power supply module 24 VDC, 15 W -

COMMUNICATION CP 01 011 Communication processor RS-485 (Modbus RTU), 1 port 1 MODULES

I/O MODULES Analog input, AI module (current) • Current measuring range: 0…20 mA, 4…20 mA AI 04 011 • 4 channels 4 • Resolution: 24 bits (including sign and overflow) • Operating error under normal conditions: ±0.1% • Common galvanic isolation

Analog input, AI module (thermal resistances, thermocouples) • Thermal resistance measurement range: 20…400 Ohm • 2 channels AI 02 031 • Supported thermal resistances: Cu50, Cu100, Pt50, Pt100, 2 Ni50, Ni100 • Supported thermocouples: R, S, B, J, T, E, K, N, A-1, A-2, A-3, L • Operating error under normal conditions: ±0.1% • Common galvanic isolation

Analog input, AI module (current, voltage; high-accuracy) • Current measuring range: 0…20 mA, 4…20 mA • Voltage measuring range: 0…+10 V, -10…+10 V AI 02 041 • 2 channels 2 • Resolution: 24 bits (including sign and overflow) • Operating error under normal conditions: ±0.025% • Channel galvanic isolation • Individual ADC for each channel

23 Analog input, AI module (current, voltage) • Current measuring range: 0…20 mA, 4…20 mA • Voltage measuring range: 0…+10 V, -10…+10 V • 4 channels AI 04 051 • Resolution: 14 bits (including sign and overflow) 4 • Operating error under normal conditions: ±0.1% • Channel galvanic isolation • Shared ADC for all channels

Analog input, AI module (current, HART) • Current measuring range: 0…20 mA, 4…20 mA • 4 channels AI 04 081 • Resolution: 24 bits (including sign and overflow) 4 • Operating error under normal conditions: ±0.1% • Common galvanic isolation • Shared ADC and HART-modem for all channels

Analog output, AO module • Output range, current: 0…20 mA, 4…20 mA • 2 channels AO 02 011 • Resolution: 16 bits 2 • Operating error under normal conditions: ±0.1% • Channel galvanic isolation

Digital input, DI module • Input current: 24 VDC DI 08 011 • 8 channels 8 • Common galvanic isolation

Digital output, DO module • Output current: 24 VDC / 0.5 A DO 08 011 • 8 channels 8 • Common galvanic isolation

Digital output, DO module • Output current: 220 VAC / 2 A, 220 VDC / 0.3 A DO 04 021 • 4 channels 4 • Channel galvanic isolation

Counter/digital module • Channel supply voltage: 5, 12, 24 V • Frequency measurement ranges: 1…100 kHz • Pulse measurement range: from 1…264 (with overflow) • Operating error under normal conditions, frequency: DA 01 011 less than ± 0.01% 1/2/2 • Pulse-counting error: ±1 pulse • 1 × counter channels • 2 × DI channels, 24 V • 2 × DO channels, 24 V / 0.5 A • Channel galvanic isolation of the counter channels

BUS MODULES Bus extension module (IN, OUT), RJ-45 ST 00 011 - Includes one R200 PP 00 011 power supply module

24 automation.gp-systems.com Hardware Configuration

Mixed Topology – Star and Ring, with REGUL R500

Regul R500

Regul R200 Regul R200

Ring Topology

Regul R200

Regul R200 Regul R200 Regul R200

Star Topology

Regul R200

Regul R200 Regul R200 Regul R200

25 Dimensional Drawings

Input/Output and Communication Processor Modules

109 12,9 109 12,9 101 101

104 15 104 15

Bus Extension Module

109 109 101 101

104 49 104 49

109 26 109 101 101

104 104

131 131 109 12,9 101

104 15

109 12,9

109 101 101

104 15

104 49

109

109 101 101

automation.gp-systems.com

104 49

CPU Modules 104

109 101

104 131

131

27 EPSILON LD – IEC 61131-3 Programming and Configuration Software for REGUL Controllers

Epsilon LD is an integrated software package that provides all the tools required for configuration, programming and maintenance of all the REGUL controllers. Having one package only enables you to flexibly use the most appropriate controller series in your project without having to learn new tools and approaches. Epsilon LD supports development of applications in the following languages:

• IEC 61131-3 • FBD (Functional Block Diagram) • LD (Ladder Diagram / Ladder Logic) • ST (Structured Text) • IL (Instruction List) • SFC (Sequential Function Diagram) • CFC (Continuous Function Chart)

Network Scanner - Find all your controllers in the network for IP configuration A specially developed tool, Network Scanner, is included into Epsilon LD to find all the REGUL controllers in your network, no matter what their network configuration is. Then the same tool can be used to configure IP addresses and names of the controllers. Abstraction – Simple to start with PLC development Abstraction level in the Epsilon LD separates controller configuration from the programming part. This approach allows for a developer new to PLC programming or to the use of REGUL controllers, to have a faster start with the system. Visual PLC Editor It is highly supportive to visualize the configuration of the system and have a clear understanding which rack contains which modules and visibly identify the state of the racks. To perform it, the software shows each system configuration in the visual editor, with drag-and-drop adjustments. Redundancy Configuration As the redundancy is at the core of the REGUL controllers, it was important to have a convenient tool to set up and monitor redundancy state. The tool allows you to see the type of the redundancy used in the system in the Visual PLC Editor, as well as indicate controllers to be used as main and hot-standby, compare firmware and application used in each of them, and switch the control from one to another. Programming - Wide choice of languages to your taste The modular structure of the projects in the Epsilon LD software supports the use of different languages more suitable to different parts of the application. IEC 61131-3 are integrated into the software and the developers can choose the preferred language for them. Additionally, there is support for CFC (Continuous Function Chart). Since the application could be split into modules running with a different speed, each of the modules can use its own language too.

28 automation.gp-systems.com

Online Software Update One of the most distinguished features is the support of the live software update on the redundant systems without stopping them from the operation. When performing an update, the control is switched to the second controller while in hot-standby. Then, the application update is uploaded to the first controller and the control is switched back to it. After successful pickup of the new application, it is synchronized to the standby controller. Profiling Each project in the Epsilon LD is developed in its own profile and you can keep as many as needed. Separate profiles allow you to get the same environment as when the application was developed. Reducing the need to search and fix library dependencies. Integrated Visualization Oftentimes, the requirements for visualization are less than the use of a SCADA system. In those cases, developers can create an interface directly from Epsilon LD and download it to the controllers. There is support for two types - one is Target Visualization, when it is displayed on an HMI (for example, R400) or on a monitor connected to the CPU module; the second is Web Visualization available in corresponding versions of the CPU modules. In case of Web Visualization, a web server runs in the module supporting remote connection and remote display of the state and control of PLC in the defined interface. Integrated Debugger Once the application is developed, use the debugger to go step-by-step through your application to ensure smooth and correct running. Remote Diagnostics and Maintenance Design of the controller to be used in the locations that are difficult to reach or the travel takes plenty of time puts a special accent on the possibility to remotely diagnose and update controller. This is reached by the integrated tools in the Epsilon LD software that support collection of the diagnostic information, analysis of the operation, and update where necessary. This includes configuration of the I/O modules, update of the application, firmware update. Real-Time Operation Before download to the controller, the application is compiled into a package for real-time operating system in the controller. Operation under it allows each REGUL controller to deliver stable and secure performance in the industrial environments.

29 Industrial Solutions and Examples Oil and Gas

Fiscal Metering – Control System for Lease Automatic Custody Transfer (LACT) Units With the focus in the oil & gas industry shifting from exploration to optimizing current operations, Lease Automatic Custody Transfer (LACT) units come forward in increasing efficiency of the oil transfer and providing more accurate accounting, collected at the SCADA level.

The system is an improved-accuracy fiscal metering system for LACT units, able to measure, compute, and store data on oil: • Volume • Quality (density, viscosity, humidity) • Flow • Pressure and pressure drops • Temperature

The system is made of a PLC (R600, R500, or combination of R400 HMI with R200 modules), high-accuracy analog input modules (AI 08 041 or AI 02 041) with just a 0.025% margin of error, and a specialized I/O module with integrated algorithm for LACT units (DA 03 011 / DA 01 011). The use of the latter modules ensures calibration unit control and the reception of the signals from flow meters in a timely and accurate manner. To the system could be connected external devices, like a printer, for example, via USB ports, monitors via VGA (R600) or DVI (R500) interfaces on the CPU modules.

The entire visualization process for the system is implemented in one project together with the preset functions. All the information from the REGUL RX00 controllers is communicated to the redundant servers and to the LACT unit workstation. The system could be connected to most major SCADA systems available on the market.

When using R200 I/O modules, additional protective seals could be added, to protect against unauthorized module replacement.

30 automation.gp-systems.com

Technical specifications (depending on the system’s type of built-in software)

General Configuration options: Measurement lines 12 Density transducer types pulse (Solartron, Sarasota) analog Flow transducer types • mass • volume • ultrasound Calibration specifications of the flow • constant ratios in the working range transducers • constant ratios in subranges • piecewise linear approximation Calibration settings • unidirectional • bidirectional • compact provers Electrical supply • Current type • DC • Voltage • 24V Operating environment • Ambient temperatures • +10°C … +40°C • Relative humidity • 35–70 % • Atmospheric pressure range • 84–106.7 kPa

Basic metrological specifications Relative error of input signal measurement • DC • <0.025% • In the frequency mode • <0.01% • In the pulse count mode • <1 pulse • Absolute error of density • <0.01 kg/m3 calculation Relative error of software and data- processing algorithms • Oil mass calculation • <0.002% • Oil volume calculation • <0.0004% • Working flow transducer ratio • <0.025% Relative error of measurement of • Oil gross weight • <0.05% • Oil net weight • <0.05% • Oil volume • <0.025%

Calibration methods Pipe/piston calibration unit of Grade One with a MI 2974-2006 comparator • MI 1974-2004 turbine flow transducers • MI 3380-2012 volume flow transducers • MI 3151-2008 mass flow transducers • MI 3272 flow meter transducers

Calculation methods Density: R 50.2.076-2010 “State standards on oil and oil products density. Calculation methods. Program and adjustment table.” Oil volume: State standard GOST R 8.595-2004 “Oil and oil products mass. General requirements for calculation methods.” Oil mass: State standard GOST R 8.595-2004 “Oil and oil products mass. General requirements for calculation methods.”

31 Control System for Oil Pumping Stations

Programmable logic controllers (PLCs) for oil pumping stations and in tank farms are required to support of large number of I/O channels and reliable operation. All the while supporting hot-standby redundancy and hot-swappable modules for fast and convenient maintenance. Control systems put into operation for these applications, with the use of REGUL RX00 controllers, satisfy in full those requirements. The I/O channel capacity for these systems often yields 3,000 and more channels. Each RTU cabinet houses two or three racks with I/O modules. The internal bus between racks utilizes connection over twisted pair cables while between the cabinets are used twisted pair or fiberoptic links. The architecture of the REGUL PLCs allows swapping RJ45 bus extension modules with fiberoptic modules and using off- the-shelf cables and connectors. The REGUL solution has a standard 3-level structure:

The top level of the system is made of an HMI or operator workstation, server hardware, and SCADA system with support of Modbus TCP, OPC DA/UA, and/or IEC 61870-5-104 protocol.

The middle level contains a central controller cabinet with redundant CPU racks, communications modules, communication controllers (if necessary), and remote terminal unit (RTU) cabinets. The PLCs used at this level are usually of the Regul R600 or R500 series, supporting in full various options of redundancy.

The lower level is represented by sensors and actuators in the configuration specific to each project.

Data collection • Collection of signals from analog, digital, intelligent transducers, and from process parameter sensors at the lower level of the control system • Display of necessary information about process and equipment status • Management of visual and sound alarms • Generation of trends of process parameters • Archiving of the process parameters, events, and actions of the operators and supervisors Monitoring and control • Status monitoring and control of process equipment from operator rooms and from local, regional, territorial, and central control centers • Automatic control of process parameters in accordance with preselected control criteria • Communication with other systems and equipment in a facility • Automatic, remote, and manual control of process equipment and actuators Handling of emergency situations • Automatic protection and control interlocking of process equipment • Identification of emergencies and of divergences of the process from preset modes • Automatic engagement of backup equipment according to predefined algorithms

32 automation.gp-systems.com

Diagnostics • Hardware and software self-diagnostics • Diagnostics of the communication channels • Security • Protection against unauthorized access

Structural Scheme: Remote I/O Redundant Ring-Type Network

Dispatch Center Main Operator Workstation

Operator Room RTM Backup Control Backup Operator Workstation Unit Server Cabinet FFDI Operator PC Operator Workstation

Main Router NTP Backup Router FFDI RTM Server Main L3 switch; Backup L3 switch; technological data technological data Top-level STM Communication Channel transmission network transmission network to dispatch center to dispatch center

Ethernet

Marshalling Panel Room

Control System Central Control Cabinet

Alarm Panel FFDI Backup Operator PC

Control System Control System Control System Control System Switch Switch Switch Switch

IN OUT Main STM Communication Controller ST 02 011 PP 00 011 ST 02 021 CU 00 061

IN OUT IN OUT Backup STM I/O Communication Modules, Controller ST 02 011 PP 00 011 ST 02 021 ST 02 011 PP 00 011 ST 02 021 CU 00 061 RS-485 IN OUT ST 02 011 PP 00 011 ST 02 021 CU 00 061

IN OUT

IN OUT I/O Modules, IN OUT IN OUT I/O I/O ST 02 011 PP 00 011 ST 02 021 ST 02 011 PP 00 011 ST 02 021 CU 00 061 RS-485 IN OUT IN OUT Modules, Modules, ST 02 011 ST 02 011 PP 00 011 PP 00 011 RS-485 ST 02 021 RS-485 ST 02 021 IN IN OUT OUT To automated system controlling sampling skid To MPAS of LACT Unit To MPAS of Multiphase Pump Station To MPAS of Tank Farm To MPAS of Fire-Fighting

IN OUT IN OUT IN OUT I/O I/O I/O Modules, Modules, Modules, ST 02 011 ST 02 011 PP 00 011 PP 00 011 ST 02 021 ST 02 021 ST 02 011 PP 00 011 RS-485 ST 02 021 RS-485 RS-485 IN OUT IN OUT IN OUT

RTU.1.1 RTU.1.2 RTU.1.3

IN OUT IN OUT IN OUT I/O I/O I/O Modules, Modules, Modules, ST 02 011 PP 00 011 ST 02 021 ST 02 011 PP 00 011 ST 02 021 ST 02 011 PP 00 011 RS-485 ST 02 021 RS-485 RS-485 IN OUT IN OUT IN OUT

Control Panel Indoor Switchgear Switching and Control Panel

IN OUT IN OUT IN OUT I/O I/O I/O Modules, Modules, Modules, ST 02 011 ST 02 011 ST 02 011 PP 00 011 PP 00 011 PP 00 011 RS-485 ST 02 021 RS-485 ST 02 021 RS-485 ST 02 021 IN OUT IN OUT IN OUT

RTU.2.1 RTU.3 RTU.4

IN OUT IN OUT IN OUT I/O I/O I/O Modules, Modules, Modules, ST 02 011 ST 02 011 ST 02 011 PP 00 011 PP 00 011 PP 00 011 RS-485 ST 02 021 RS-485 ST 02 021 RS-485 ST 02 021 IN OUT IN OUT IN OUT

33 Control System for Gas Pressure Regulators

The control system for gas pressure regulators is designed to ensure automatic control of the gas supply to the customer. The system provides flexible process automation and real-time control of the major technological parameters. It implements various scenarios involving the major equipment functions.

Structure The control system for gas pressure regulators is based on the REGUL R400 programmable logic controller and the R200 distributed I/O system. The system is equipped with adapters and spark-protection barriers to safely connect measurement equipment and actuators.

The REGUL R400 also plays the role of an operator console used to set the system and process the parameters, visualize technological information, and show events and a breakdown history on the panel display. Additionally, information can be sent to outside systems via digital communication channels (RS-485 and Ethernet). Besides the control system, the following equipment is necessary: • A gas pressure regulator with a remote parameter control function • An input pressure transducer • An output pressure transducer • A gas meter

Major functions • Remote control of the natural gas pressure and flow at gas distribution stations • Automatic control of the natural gas pressure and flow in accordance with a preset scenario • Status monitoring and equipment checks • Gas supply optimization and energy efficiency improvement (due to the keeping of the preset natural gas flow to smooth down peak loads and the use of the gas transport system as a gas storage facility) • Prevention of gas flow exceeding the gas meter range (gas meter overload protection) • Safety valve duplication (control of the pressure sensor activation signal) • Management of multithread systems with shock-free thread activation/deactivation and a uniform load distribution among the threads

The joining of the functionality of the two systems into one by a slight functional add-on can be implemented by the gas distribution station control system.

34 automation.gp-systems.com

Structural scheme of gas pressure regulator controls

Ethernet TCP/IP RS 485 PLC Regul R400

EtherCAT

PLC Regul R200

PU PD PT Qb PT Gas Pressure Qn Transducer P Gas Pressure T Transducer

Gas Flow Corrector

Pressure After the Regulator Pressure Before Gas Pressure the Regulator Regulator Gas Meter

35 Fire and Gas System

Another example of a distributed system based on the architecture similar to that of an oil pumping station’s control system, is the REGUL Fire and Gas System. This system is used in oil and gas production and in transport and storage facilities to configure fire alarm and fire-extinguishing systems of different types and complexities.

The REGUL Fire and Gas is a flexible system with a variable set of components based on REGUL R500 and REGUL R600 programmable logic controllers with the support of redundancy and the hot-swapping of modules. The system is designed to: • Detect fire and unauthorized entry in protected areas, including indoor and outdoor installations at a risk of explosion • Execute automatic remote control of water-cooling tank units and different types of fire-extinguishing systems including spray, water, foam, gas, powder, etc., both separately and in various combinations • Send alarms and alerts to higher-hierarchy equipment such as operator workstations and to adjoining systems such as SCADA, automatic process control systems, central surveillance rooms, etc. • Control, monitor, and protect technological equipment

System structure

HMI equipment (operator workstation) and a SCADA system supporting Modbus TCP, OPC, and IEC-61870-5-104 protocols. REGUL R500 and REGUL R600 programmable logic controllers. Overall, this level includes: • A central control cabinet, based on hot-standby CPU modules • Cabinets with I/O racks • Network for data transfer between the I/O racks, CPU racks, control center • An alarm panel cabinet Sensors, transducers, alarm announcers, light and sound alerts, and actuators.

Diagnostics • Performs self-testing of software and hardware and automatic monitoring of the communication lines (for wired lines for breakdowns and short circuits, for fiberoptic and digital lines – for communication failures). • Communication failures are detected on the lines: • With equipment that forms starting signal • With fire-extinguishing system devices (notifiers, alarm panels, electric valves, explosive cartridges, fire pumps, dosage pumps, fans, electric drives, etc.) Redundancy and notifications • Automatically switches power supply from the main line to backup line and vice versa, with a corresponding indication. • There is an option of switching from automatic process control to remote (manual) and back. • Notifications about fire event, signals of activating fire-extinguishing system and/or of tank water cooling are flexibly programmed as scenarios.

36 automation.gp-systems.com

Control and monitoring • Collects signals from security, fire and security, or fire notifiers. Addressing of the notifiers is done over the RS- 485 interface with Modbus RTU protocol by connecting each notifier to a separate input in the system. • Collects signals from the detection devices and other equipment impacting algorithm of operation (in case it is present in the system) • Other equipment could be connected to the system over Ethernet or RS-485 interfaces (process control system, telemechanic devices, etc.) • Collects electric signals from sensors monitoring functional state of the equipment (position, pressure, temperature, etc.) Control • Forms control signals for notification, evacuation, smoke and gas removal, etc. • Priority logging and transmission into external systems notifications on fire, in respect to other signals are formed by the system • Controls light and sound alarms • Indication of activation of fire extinguishing system and/or tank water cooling, with indication of directions

Access control • Prevents unauthorized access to the system • Visualization and archiving • Displays all the required information, including status of the equipment • Forms trend lines for the selected technological parameters • Archives selected technological parameters, events, and actions of the operators

Visualization and archiving • Displays all the required information, including status of the equipment • Forms trend lines for the selected technological parameters • Archives selected technological parameters, events, and actions of the operators

37 Structural Scheme: RTU Redundant Ring-Type Network

Dispatch Center Main Operator Workstation

Firefighter (FF) Operator Room Post/Security Post RTM FF Workstation (without control Backup FF Workstation Server Cabinet functionality) FFDI Operator PC

Main Router NTP Backup Router Server FF RTM

Main L3 switch; Backup L3 switch; technological data technological data Top-level STM Communication Channel transmission network transmission network to dispatch center to dispatch center

Ethernet

Marshalling Panel Room Fire Extinguishing Pumping Station Room №

FDDI IN OUT IN OUT Аlarm Panel IN OUT Backup Operator PC I/O Modules, I/O Modules, I/O Modules, RS-485 RS-485 Display RS-485 ST 02 021 ST 02 021 ST 02 021 ST 02 011 ST 02 011 ST 02 011 Switch Switch PP 00 011 PP 00 011 PP 00 011 IN OUT IN OUT IN OUT

IN OUT ST 02 021 ST 02 011 PP 00 011 CU 00 061 FF Central Cabinet FF Remote Cabinet.1 FF Remote Cabinet.2 FF Remote Cabinet.3

IN OUT

I/O Modules, RS-485 ST 02 021 ST 02 011 PP 00 011

IN OUT To MPAS of LACT Unit To MPAS of Multiphase Pump Station To MPAS of Booster Station To MPAS of Tank Farm

IN OUT IN OUT IN OUT

I/O Modules, I/O Modules, I/O Modules, RS-485 RS-485 RS-485 ST 02 021 ST 02 011 PP 00 011 CU 00 061 ST 02 021 ST 02 021 ST 02 021 ST 02 011 ST 02 011 ST 02 011 PP 00 011 PP 00 011 PP 00 011 IN OUT IN OUT IN OUT IN OUT

38 automation.gp-systems.com Telemetry Solution

The built-in IEC 60870-5-101 and IEC 60870-5-104 telemetry protocols are a natural fit for creating a telemetry system for the oil and gas industry based on the REGUL RX00 controller.

The software/hardware telemetry solution is designed for use in the telemechanic systems that ensure centralized monitoring and remote control of linear long-distance oil pipeline equipment and other facilities related to oil and gas production and long-distance pipeline transportation.

In general, the telemechanics of the linear parts of long-distance pipelines has the following functions for each monitored site:

Alerts • Valve status and position • Cleaning and diagnostic agent status • Valve actuator failure and breakdown • Line disconnection and switch status and position • Presence of voltage in a transmission line along the route • Minimum and maximum control room temperatures • Maximum level in the leakage accumulator at the scraper launcher-receiver • Pressure-tap well flooding at trunk pipeline water barrier crossings • Scraper launcher-receiver flooding at trunk pipeline crossings of water barriers • Leakage at scraper launcher-receiver at trunk line underwater passage • In the absence of a separate transmission linear protection system and access control: • Security alarm system status (control room, pressure takeoff wells) • Fire alarm system in the control room • Perimeter surveillance alarm system at scraper launcher-receiver at trunk pipeline launcher-receiver • Alarm system of air escape valves located in the line valve unit

Control • Line valves • Command verification equipment (“control” and “unblock” commands) • Security alarm system (security alarm “unblock” command) • Circuit breakers and switches along transmission lines • Security lighting

Measurements: • Actual pressure in the trunk pipeline • Oil flow along the trunk pipeline • Actual pressure in the disconnected backup lines in underwater passages • Actual pressure in access chambers of passing, launching, and receiving of scraper outside pump station • In the absence of a separate remote-controlled system of the cathode protection station: • Electric current of the cathode protection station • Voltage of the cathode protection station • Protective “pipe-ground” potential • Voltage at the electrochemical protection drainage point

39 Teleregulation • actuator positions of the linear pipe control system • Output voltage (current, protective voltage) of the electrochemical protection station

Communication • Send data necessary for the functioning of the leakage detection system (if required) • Exchange data with the telemechanic equipment of the pump station, backup control center, and transit drain station via IEC 60870-5-101 and IEC 60870-5-104 telemechanic protocols

Gas Odorizing Control System

The odorizing unit control system is designed to automatically control the process of supplying odorant to a gas pipeline in proportion to the actual natural gas flow with a given degree of odorizing. Structure The odorizing unit control system is based on the REGUL R400 programmable logic controller and the REGUL R200 I/Os. The system is equipped with adapters and spark-protection barriers to safely connect measurement equipment and actuators.

The REGUL R400 plays the role of an operator console to set the system and process parameters, visualize technological information, and show events and a breakdown history on the panel display. Additionally, information can be sent to external systems via digital communication channels (RS-485 and Ethernet) or printed out as reports. Major functions • Supply odorant at a required concentration in proportion to the gas flow • Control supply of the odorant (feedback from the flow controller) • Monitor level of the odorant in the supply tank • Monitor pressure monitoring in the supply tank • Log events and breakdowns • Generate reports • Print reports (via a USB/Ethernet-connected printer) • Control access according to the user permissions • Transfer information via RS-485 (Modbus RTU) and Ethernet (Modbus TCP) • Store data on an external USB flash drive

40 automation.gp-systems.com Power Generation and Distribution Thyone - Protection and Control System for Steam and Gas Turbines Rapidly and continuously changing technological processes in the turbines require reliable high-speed control systems with an emergency shutdown (ESD) function.

The Thyone solution for steam turbines was developed as a system with redundant configuration, extended to cover maximum availability. The system can automatically control a steam turbine in standard and emergency modes (of generation unit and of the power system), while monitoring load, live-steam pressure, positions of the control valves, signals from control devices at power unit/station/system.

Range of turbines to be used with Thyone varies from the small turbines for industrial applications to the large 800 MW and more powerful turbines. The solution can be used with the steam turbines for the power unit participation in primary and secondary frequency control.

The redundancy is implemented at the levels of PLC, control, measurement equipment. And the solution provides timely diagnostics of the individual systems and control circuits of the actuators.

Implementation of the solution with the use of REGUL R600 (R500) PLCs allows a flexible configuration, connection to a remote SCADA (with support of the most common vendors on the market). Hot-standby operation of the CPU units and hot-swappable modules allow for a stable and continuous operation of the system. Major functions • Steam pressure control, with alignment to the power system frequency • Pressure control throttle (adjustment of live-steam pressure before the turbine) • Turbine protection against an inappropriate reduction in steam pressure • Sliding pressure operation (control mode with variable live-steam pressure) • Activation of the turbine’s control valves when the electrical load is dropped • Activation of the control and shutoff valves in case of increased frequency and acceleration • Turbine shutdown (via relay channel) without disconnecting the generator from the grid • Control of turbine rotation speed • Short- and long-term emergency load release of the power unit, with restoring load by the signals from emergency automation. By the conditions for dynamic and static stability. • Deep system diagnostics • Deep system diagnostics At the core of the Thyone solution is DA 03 011 custom-designed counter/digital module with integrated software algorithms and frequency generator. Depending on the selected internal subprogram, it can: 1. Measure frequency over three channels in two ranges (up to 10 and up to 500 kHz). 2. Provide turbine overspeed protection, together with TMR electronic overspeed trip; verify protection state on a stopped turbine or during idling from a built-in generator. 3. Receive signals from an incremental encoder (control of the actuator position). 4. Receive signals from flow meters and control calibration setting for flow meter calibration. System specifications • 100% redundancy (including RTU modules) • Generation of control actions in 10 ms • Protection against issuing false control signals • Archiving in 10-ms, 100-ms, and 1-s intervals • Implementation of hot-standby redundancy of control channels for 20 ms • Hot-swapping of the PLC modules • Heavy-duty operating conditions • Mean time between failures of at least 100,000 hours 41 Tarvus – Electronic Overspeed Trip for Steam and Gas Turbines

Turbine overspeed protection is one of the critical areas in turbine control, and electronic trip systems can come useful, especially when the rotation speed is at 10 000 rpm or more. The Tarvus system was designed as an electronic overspeed trip that can be used on new turbines or could be retrofitted into an already installed system. The range of turbines covered is from small industrial to large power industry turbines.

The Tarvus system measures the rotation frequency and compares it with an emergency setpoint. When a critical speed is reached, the system sends a digital signal to stop the turbine while taking into account its acceleration. That is, if there is acceleration, the Tarvus recalculates and reduces setpoint so that the rpms don’t overshoot the critical value.

Equipment configuration The system is Triple Modular Redundant (TMR) and is built around frequency measurement DA 03 021 custom- designed module with integrated software and frequency generator. The system has three of these modules, and each is connected to one or two frequency sensors.

The power is supplied to the modules and sensors from separate external power sources. Discrete signals are joined together in the external majority circuit according to 2-out-of-3 principle.

To perform safety checks when the turbine is shut down, the system switches from sensor input to the frequency generator, built into the DA 03 module. The generator provides a set frequency to the measurement circuit, taking into consideration acceleration.

The CPU module in this systems server only to perform diagnostics and to generate tasks for the tests.

Data bus

CPU DA DA DA MP MP MP

CPU

CPLD CPLD CPLD

Peripherals Peripherals Peripherals Generator Generator Generator

D D D

42 automation.gp-systems.com Automatic Load-Frequency Control System

The Automatic Load-Frequency Control (ALFC) system regulates active power and frequency of the power units under its control to take part in the secondary (sometimes tertiary) frequency regulation. The system ensures that the group of automated power stations (power units) provides optimal frequency, according to the requirements and situation of the grid.

The system receives control signals from the centralized system for automatic power and frequency control and adjusts the load and frequency of the group. Operating parameters (secondary frequency regulation, rated primary frequency regulation, sustained turbine fast-valving signals) are communicated to the servers from the REGUL R600 PLC via ARTI3 protocol. Diagnostic information from the switches is communicated via the SNMP protocol.

The system is made as a cabinet with programmable logic controllers, servers, commutators, and HMI panel. System Components • 2 x REGUL R600 programmable logic controllers in hot-standby configuration: • 24 VDC power supply module • R600 CU 00 061 central processor unit • Communication processor module with 4 x RS-485 ports with Modbus RTU and IEC 61870-5-101 • Digital input module, 32-channel, 24 VDC with group galvanic isolation • HMI panel in the cabinet door • 2 x servers (main and backup; fan-free) • 2 x commutators (main and backup) • Power supply, protection, and lighting and cooling equipment Communications • Simultaneous cyclic two-way data exchange between power units and ALFC system over RS-485 in Modbus RTU protocol, with the speed of at least 9,600 bit/s • Simultaneous cyclic two-way data exchange between ALFC system and central system for automatic power and frequency control over IEC 61870-5-104 protocol • Communication cycle of less than 1 s between the automatic power control systems of the power units and centralized system for automatic power and frequency control • Transmission of the data on load-frequency control and rated primary frequency regulation to the plant’s SCADA system • Clock Synchronization • All measurements and signals from remote units are bound to the astronomical time with accuracy of maximum 100 ms • Internal clock of the system is synchronized with the astronomical clock via an NTP server in the power plant’s network Redundancy • CPU modules of the PLC operate in hot-standby mode with redundant synchronization channel • Archiving servers are redundant with automatic data synchronization • Constant self-diagnostics and generation of alerts • The system constantly monitors status of the communication channels with the central system and with the power units control systems, logs errors, forms corresponding signals • Automatic selection of a functioning communication channel in case of restored operation

43 • Suspension of data transfer between the power units and centralized system in case of failure of both channels in one direction Turbine Control • The PLC in the system runs algorithms for the automatic load-frequency control and for the turbine sustained fast- valving • Signals from the emergency control system for fast-valving are received via “dry contact” (voltage-free) connection Data Archiving • Archiving of data on changes in the time to collect parameters for automatic load-frequency control, rated primary frequency regulation, turbine sustained fast-valving • Archiving of the events on appearing and disappearing of inaccurate data • Archiving of the events on system operation, including modification of the tools and software • All the archived data is stored for at least 3 months Monitoring and Reporting • Included HMI visualizes operation of the system functions in form of tables, charts, reports • The system can provide reports on the hardware and software state of the components • Automatic or ad-hoc generation of the text files in the approved format with the changes in rated primary frequency regulation with 1 second steps • Transfer of the archived files to the dispatch office over main or backup communication channel via FTP protocol

44 automation.gp-systems.com Turbo-generator Vibration Monitoring System

Monitoring turbo-generators for state of vibration and mechanical parameters, and providing timely diagnostics and notification of the operators are important for anticipating failures of the units and improving stability of their operation.

The system, developed by engineers of GP Systems GmbH, connects to the sensors of mechanical parameters via secondary convertors. The converters send output signals of instantaneous values and unified 4…20 mA signals. Signals with instantaneous values connect to the system’s computer with the multi-channel ADC and Vibration Monitoring software that calculates and charts data for the diagnostics of: • Harmonic parts of the vibration • Rotating parts of the vibration • Low-frequency vibration • High-frequency vibration • Surges of values of parameters • Coefficient of vibration amplitude

Unified outputs of the converters are connected to a REGUL controller. In the controller are implemented all the protection and blocking algorithms, comparison of parameters with setpoints and notification on the overruns, forming of relay signals to an alarm and protection system.

To provide the required availability of the system are used two CPU modules of REGUL controller, redundant bus connections, redundant power supplies, and signals in the protection part are connected to different I/O modules.

A touch panel is installed in the cabinet for the configuration of setpoints, setup, masking, calibration of the channels, and for visualization of the selected parameters.

45 MS5002E (Mark VIe) Gas Turbine Control System

This gas turbine control system was developed on the base of REGUL R600 PLC. There are 3 racks with redundant power supplies. All the signals used in the turbine technological protections are connected to different modules, installed into different racks to exclude failure for a common cause. Features • The system monitors technological parameters of the turbine and controls valves for fuel and air supply, exhaust gases, and direction of distributor. • Application cycle time – 20 ms. • All signals, used in the emergency shutdown systems of the turbine, were connected to separate modules, installed into separate racks, to exclude failure for a common cause. • The MS5002E turbine has two axles. Operating frequencies of the axle rotation - 6000 and 7000 RPM. Due to this, there are 2 turbine rotations/power regulators and two overspeed trips. For this were installed 6 frequency sensors on the turbine (three on each axle). • Frequency counters were connected to DA 03 021 modules of REGUL R600. These modules measure frequency over 3 channels for the regulation functions and have built-in overspeed protection.

46 automation.gp-systems.com Other Industrial Converter Gateway

A converter gateway receives data via various protocols, converts it into its proprietary format, and sends data to use by another protocol. This approach provides no direct connection between the networks and allows to divide them, increasing the security level in the system. Communication gateway converter is designed to: • Receive data via OPC DA 2.0/3.0, OPC UA, and IEC 60870-5-104/IEC 60870-5-101 protocols • Convert the received data and transfer it via IEC 60870-5-104/IEC 60870-5-101 and Modbus RTU/Modbus TCP protocols

Features • 1 x RS-232 interface (exchange protocol: Modbus RTU or IEC 61870-5-101) • 1 x RS-485 interface (exchange protocol: Modbus RTU or IEC 61870-5-101) • 2 x RJ45 Ethernet interface (exchange protocols: OPC DA 2.0/3.0, OPC UA, IEC 61870-5-104) • Maximum speed of float-type parameter transfer via Modbus RTU protocol is 1,000 parameters/s • Maximum speed of float-type parameter transfer via IEC 60870-5-101 protocol is above 1,000 parameters/s depending on the frequency of the data status changes

A converter gateway can be implemented with any series of REGUL RX00 controllers.

For the power generation and distribution, the function of the gateway converter is performed by the automatic load-frequency control system.

47 GP Systems GmbH Ochshäuser Str. 45, 34123 Kassel, Germany tel.: +49 (561) 820 93350 [email protected] automation.gp-systems.com