Microcontroller based Remote Terminal Unit Universal Card in Reactors

    RTU-UNIVERSAL card is a microcontroller based module developed to process Digital inputs, Analog inputs and Relay outputs of any real time data acquisition system used in process industries like nuclear power plants. This AT89C51RD2 based card focuses on the development of diagnostic software in C language to process digital inputs, analog inputs and relay outputs as well as checking the healthiness of RTU–Universal module. It acquires field signals from various sensors like K-type thermocouples, Limit Switches, Transmitters, and Leak Detectors etc. and sends digitalized data packets through Ethernet to the nearest LCC for Distributed Digital Control System (DDCS) display. The module also generates control outputs in the form of potential free contacts to Control Heater, Valves, etc
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    ORIGINAL POST
    By S. Bhargavi1 , R. Manohari2
    components
    Hardware Components
    NM7010B+
    X 1
    AT89C51RD2 MICROCONTROLLER
    X 1
    MAX 232A – RS232 DRIVER/RECIEVER
    X 1
    DS 1554 Real Time Clock IC
    X 1
    details

    Screenshot 2022-08-08 120341.png

    I. INTRODUCTION
    Nuclear electricity in India is presently from Pressurized Heavy Water Reactors (PHWRs). Presently 15 reactors are operating, and 8 more are under construction. With 250 reactor-years of operating experience, India is one of the advanced countries in nuclear energy. PHWRs will saturate at about 10 GWe. In order to satisfy the energy requirements, with fuel derived from internal resources, it is possible to build FBRs with energy capacity. It is estimated that, indigenous Fast Breeder Reactors (FBRs) will contribute 200 GWe by 2052. This will account for about 16 % of total energy production in at that time.
    A nuclear reactor and process control systems consists of various continuous process signals from the various sensors and transmitters placed at different locations in the field including hazardous area. The accurate measurement of these process parameters are very important in order to carry out control operation properly. This is because in high voltage transmission systems, fault levels are generally high, which if not cleared rapidly, can cause system instability as well as extensive damage and hazards to personnel. Speed of operation, selectivity, reliability and security of the trip decision assume more importance at higher operating voltages as they handle bulk of power. Hence this laid to the foundation for testing of different parameters or signals coming from the reactor/field.

    II. REMOTE TERMINAL UNIT (RTU)
    Remote terminal unit is one of the independent safety related system of PFBR. Nearly 20,000 signals from the plant are processed, stored & analyzed on this computer system thus enabling the operators and designers to access the plant data in any permutation and combination. The Reactors in the world are protected by automatic shutdown systems which become effective upon irregularities in plant operating conditions. The success of FBR can be attributed to the robust design & manufacturing practises, excellence in quality and overall, efficient personnel qualification through systematic training and reliable predictive condition management practises. The construction and working of microcontroller based RTU-Universal module is a data acquisition PFBR cards are helpful for accurate measurement.

    III. RTU-UNIVERSAL CARD
    RTU-UNIVERSAL CARD is one of the most important modules in the Remote Terminal Unit (RTU). These modules are located near the Reactor Systems and can be communicated with control block through Ethernet cables. This module has got 16 channels for Digital Inputs, 8 channels for analog inputs and 8 channels for Relay Outputs. The RTU gets the digital inputs and analog inputs from the field signals and are processed using AT89C51RD2 Micro-controller which is inbuilt in the module.

    IV.SYSTEM DESCRIPTION

    A) AT89C51RD2 MICROCONTROLLER

    B) DS 1554 Real Time Clock IC

    C) NM 7010B + REV-1.0 ETHERNET MODULE IC

    D) MAX 232A – RS232 DRIVER/RECIEVER

    V.HARDWARE DESCRIPTION
    A) TEST PROCEDURE

    B) EQUIPMENT REQUIRED
     RTU boards along with Back plane
     DC Power Supply of 5V@50A
     Analog Voltage Source (0-10VDC)
     Field interrogation voltage of 24VDC @1.6A for Digital Inputs
     Decade Resistance Box
     One RS 232 cable
     PC with OS
     FLIP GUI software from ATMEL
     Keil „C‟ Cross Compiler for software development
     I/O simulator for 16 Channel 16Channel DI-RO Board

    VI.SOFTWARE DIAGNOSTIC
    A) EMBEDDED C

    B) KEIL’S SOFTWARE

    VII.SIMULATION RESULTS

    A) RS232 Communication Test:

    B) MEMORY AND RTC TEST:

    C) DIGITAL INPUT TEST:

    D) ANALOG INPUT TEST:

    E) RELAY OUTPUT TEST:

    VIII.CONCLUSION
    RTU universal card is designed and the development of diagnostic software for UNIV-RTU has been successfully completed and various features of the board also been tested. The test software works in both manual and auto mode. In auto mode the error detection logic has been implemented for memory, DI, RO and AI test. This enable us to easily find the bit error/channel error if any. The program can further be improved to implement the diagnostic features for LAN and the test software can be downloaded to target to test LAN connectivity. This will help immensely towards transmitting and receiving packets of information via LAN and can provide data communication to/from other data acquisition and control systems in the plant.

    Screenshot 2022-08-08 120341.png

    I. INTRODUCTION
    Nuclear electricity in India is presently from Pressurized Heavy Water Reactors (PHWRs). Presently 15 reactors are operating, and 8 more are under construction. With 250 reactor-years of operating experience, India is one of the advanced countries in nuclear energy. PHWRs will saturate at about 10 GWe. In order to satisfy the energy requirements, with fuel derived from internal resources, it is possible to build FBRs with energy capacity. It is estimated that, indigenous Fast Breeder Reactors (FBRs) will contribute 200 GWe by 2052. This will account for about 16 % of total energy production in at that time.
    A nuclear reactor and process control systems consists of various continuous process signals from the various sensors and transmitters placed at different locations in the field including hazardous area. The accurate measurement of these process parameters are very important in order to carry out control operation properly. This is because in high voltage transmission systems, fault levels are generally high, which if not cleared rapidly, can cause system instability as well as extensive damage and hazards to personnel. Speed of operation, selectivity, reliability and security of the trip decision assume more importance at higher operating voltages as they handle bulk of power. Hence this laid to the foundation for testing of different parameters or signals coming from the reactor/field.

    II. REMOTE TERMINAL UNIT (RTU)
    Remote terminal unit is one of the independent safety related system of PFBR. Nearly 20,000 signals from the plant are processed, stored & analyzed on this computer system thus enabling the operators and designers to access the plant data in any permutation and combination. The Reactors in the world are protected by automatic shutdown systems which become effective upon irregularities in plant operating conditions. The success of FBR can be attributed to the robust design & manufacturing practises, excellence in quality and overall, efficient personnel qualification through systematic training and reliable predictive condition management practises. The construction and working of microcontroller based RTU-Universal module is a data acquisition PFBR cards are helpful for accurate measurement.

    III. RTU-UNIVERSAL CARD
    RTU-UNIVERSAL CARD is one of the most important modules in the Remote Terminal Unit (RTU). These modules are located near the Reactor Systems and can be communicated with control block through Ethernet cables. This module has got 16 channels for Digital Inputs, 8 channels for analog inputs and 8 channels for Relay Outputs. The RTU gets the digital inputs and analog inputs from the field signals and are processed using AT89C51RD2 Micro-controller which is inbuilt in the module.

    IV.SYSTEM DESCRIPTION

    A) AT89C51RD2 MICROCONTROLLER

    B) DS 1554 Real Time Clock IC

    C) NM 7010B + REV-1.0 ETHERNET MODULE IC

    D) MAX 232A – RS232 DRIVER/RECIEVER

    V.HARDWARE DESCRIPTION
    A) TEST PROCEDURE

    B) EQUIPMENT REQUIRED
     RTU boards along with Back plane
     DC Power Supply of 5V@50A
     Analog Voltage Source (0-10VDC)
     Field interrogation voltage of 24VDC @1.6A for Digital Inputs
     Decade Resistance Box
     One RS 232 cable
     PC with OS
     FLIP GUI software from ATMEL
     Keil „C‟ Cross Compiler for software development
     I/O simulator for 16 Channel 16Channel DI-RO Board

    VI.SOFTWARE DIAGNOSTIC
    A) EMBEDDED C

    B) KEIL’S SOFTWARE

    VII.SIMULATION RESULTS

    A) RS232 Communication Test:

    B) MEMORY AND RTC TEST:

    C) DIGITAL INPUT TEST:

    D) ANALOG INPUT TEST:

    E) RELAY OUTPUT TEST:

    VIII.CONCLUSION
    RTU universal card is designed and the development of diagnostic software for UNIV-RTU has been successfully completed and various features of the board also been tested. The test software works in both manual and auto mode. In auto mode the error detection logic has been implemented for memory, DI, RO and AI test. This enable us to easily find the bit error/channel error if any. The program can further be improved to implement the diagnostic features for LAN and the test software can be downloaded to target to test LAN connectivity. This will help immensely towards transmitting and receiving packets of information via LAN and can provide data communication to/from other data acquisition and control systems in the plant.

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