maxdna_technologydcs

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maxDNA Technology

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Metso Automation Max Controls, Inc.

1180 Church Road

Lansdale, PA 19446, USA

Tel. +1 215 393 3900

Fax +1 215 393 3921

www.metsoautomation.com



This is maxDNAmaxDNA is the latest generation of Plant AutomationSystem (PAS) from Metso Automation MAX Controls.It is the result of combining the field proven hardware,network security and human machine interface soft-ware of MAX1000+PLUS with the Dynamic Network of Applications (DNA),to deliver world class optimizationand control to power plants and other continuousprocesses. What makes the difference is that maxDNAwas created by application developers knowledgeablein the operation of various real working plants. Our

application specific software will monitor and controlprocess performance; keeping the plant operating atpeak efficiency. As an example, Loop Browser will alertplant engineering as to when and how much controltuning is needed to compensate for wear and degra-dation of major process equipment elements and de-vices throughout the plant. Metso’s goal is to increasethe return on plant and people investment for all of our clients.

Proven applications expertise

DCS maxDNA

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ADVANCED CONTROLS

CONTROLSDistributed Processing Unit(maxDPU4E)

CONNECTIVITYmaxLINKSmaxOPC

INFORMATION MANAGEMENTProcess HistorianAlarm HistorianUser Tools

OPERATIONSOperator Interface

FIELDRack I/OEmbedded I/O

KNOWLEDGE MANAGEMENTProduction diariesProcess helpsLoop descriptions

ENGINEERING AND MAINTENANCEEngineering RepositoryEngineering Tools

PLANT MANAGEMENTOperation management

Performance managementCondition monitoringProduction managementEnvironmental management

ENTERPRISE MANAGEMENT

e P o w e r

Metso Automation MAX Controls has designed, built

and installed plant automation systems for the electric

power and energy industries since its founding in

1995. It continues the Leeds & Northrup legacy that

goes back over 75 years, during which time it became

the leader in providing control and automation of

large utility generating plants.

Today,Metso Automation MAX Controls (Metso Automa-

tion) maintains a staff of highly skilled application engi-

neers with 100’s of years of combined process automation

experience.Metso application engineers are thoroughly

involved in the utility industry and are familiar with control-

ling and operating virtually all types of generating plants.

Metso Automation knows boilers by all major suppliers and

has proven solutions for tangentially-fired furnaces,front

and rear-fired furnaces,down-shot furnaces, and fluidized-

bed boilers.Metso Automation has also provided controls

for over 150 once-through boilers.

Steel making is another important market where MAX1,

MAX1000,MAX1000+PLUS and maxDNA systems are in-

stalled.Metso Automation systems are used for blastfurnace control,basic oxygen furnaces,vacuum furnaces,

reheat furnaces,hot mills,soaking pits,and annealing

furnaces. Of special interest for steel mill applications is

cogeneration, where Metso Automation systems are used

to control multiple-fuel furnace applications.

Petrochemical and refining are also applications for the

maxDNA system;entire refineries are controlled by

MAX1000 systems.Two major Brazilian petrochemical

producers have standardized on the MAX1000 and

maxDNA systems at multiple-plant sites.

One of the leading producers of integrated circuit chipsused in military,satellite communication,and critical

commercial applications,re lies on a Metso plant automa-

tion system to control the sintering of ceramic substrates

high temperature multizone,electrically fired furnaces.

Besides controlling temperatures to +/- 0.1 degree C in

each furnace zone,the system controls furnace pressure

and the flow of process gases into the furnace.The roboti

devices that move material between furnaces and pre and

post sintering operations are controlled through the Mets

plant automation system.

Complete life-cycle services for

Power (generation)Cogeneration

- conventional (boiler & steam turbine)- combined cycle

Energy-from-waste plants

Renewable energy- bioenergy- wind power (special applications)

Industrial processes

- glass and ceramics

- heat treating and metallurgical

- petrochemical and refining



maxDNA Enterprise and Plant Management applica-

tions are designed to support the decision-making of

corporate/plant management and to assist operation,

production and maintenance personnel in their every-

day work. These applications provide cutting edge

tools to improve operations, optimize performance

and manage the economics in an environmentally

friendly manner.

The Enterprise and Plant Management applications are

tailor-made to meet each customer’s specific require-

ments. The information management activity and the

enterprise and plant management solutions are seam-

lessly linked to the overall network of applications,

which guarantees efficient collaboration between

management and plant control.The modular structure

enables the customer to precisely select the features

needed – to allow flexible future growth.

Enterprise Management consists of tailor-made solutions

for the overall energy management of power utilities and

industrial corporations owning and operating several pow-

er plants.

The maxDNAPlant Management solutions include appli-

Enterprise and Plant Management

(kg/s, MW, etc.). Advanced calculation procedures are uti-

lized to obtain more accurate information about process

performance, as compared with data which can be ob-

tained by basic calculations and measurements alone.

Condition Monitoring applications are used to address spe-

cific issues,such as corrosion,cleanliness,fouling,mechan-

ical condition,vibration – i.e.items specific to the condition

of the plant’s main equipment.The measured and calculat-ed information can be used to improve the performance

of the main equipment,schedule washes and maintenance

work, and to minimize the risk for potential damages.

The Production Management applications are used to de-

velop the operational strategy of the power plant covering

both production, procurement and planning. Production

Management includes applications for demand forecast-

ing, simulation and optimization. These applications can

be used as an off-line planning tool (input data selected

by the user) or as an on-line tool (actual, real-time process

data are used as the basis for optimization), assisting the

management and production personnel in operating the

plant.

The Environmental Management applications address the

environmental issues related to the power plant. Environ-mental Management includes applications,which are used

cations specifically developed to efficiently and precisely

monitor and analyze the operation, and optimize the per-

formance of a single power station or an industrial-type

cogeneration plant. The standardized plant management

applications are customized individually for each customer.

The Operation Management applications report basic infor-

mation on power plant operations, including heat a nd

power production, fuel and power consumption, overallefficiencies,start-ups,shutdowns and running times.Stan-

dardized Operation Management applications are avail-

able for different types of plants:power stations,combined-

cycle cogeneration plants, energy-from-waste plants and

others.

The detailed performance of the power plant, its main

equipment and auxiliary systems,is monitored and report-

ed upon by Performance Management applications. ThePerformance Management applications are available for dif-

ferent types of boilers, steam and gas turbines and power

plant auxiliary systems, such as fuel handling and bottom

ash systems. The calculated and reported parameters in-

clude main equipment efficiencies (%), specific consump-

tion figures ([kg/s]/MW, MJ/MWh, etc.) and more detailed

equipment specific production and consumption figures

Enterprise Management

Plant Management

Operation ManagementPowerCogenerationEnergy-from-waste

Performance ManagementBoilers (fluidized bed,grate,oil/gas, etc.)Steam turbinesGas turbinesHeat recovery steam generators

Condition MonitoringBoilers (fluidized bed,grate,oil/gas, etc.)Steam turbinesGas turbinesHeat recovery steam generators

Production ManagementDemand forecasting,simulation and optimization

Environmental ManagementEmission MonitoringPermit MonitoringAuthority ReportingContinual Improvement

maxDNA Plant Management consists of applications specifically developfor the energy industry to improve operation,optimize performance anminimize costs in an environmentally friendly manner.The Plant Manag

ment applications are designed to assist in all areas of power plant operatio– from management to production and maintenance.

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to monitor gaseous emissions, wastewater, solid waste

heat losses and other emissions into the ambient.Applic

tions for Permit Monitoring and Authority Reporting assi

the power plant personnel in the necessary follow-up an

reporting of environmental parameters.The environment

awareness of the entire power plant personnel can be e

hanced with the Continual Improvement application.



Knowledge Management Information Management

maxDNA provides an organization with revolutionaryknowledge management tools,which expand the appli-cation network into an efficient decision support system.They bring design knowledge to operational situations,so that the re quired on-target guide is just a click away.The knowledge is also usable in the toughest situations.Knowledge Management tools such as the diary andthe process helps, which store and allow the sharing of experience, help to enhance continuous learning andthe development of operational practices.The maxDNAKnowledge Management builds up an “organizationmemory” which boosts the performance and learningof the production staff. Metso Automation is a leadingsupplier in the field of managing operation knowledge.

The key benefits:

• Transferring on-target design knowledge to help inoperational situations

• Storing, sharing and accumulating experienceknowledge

• Changing tacit knowledge to explicit knowledge• Efficient building of organization memory• Continuous learning• Clear situation awareness• Efficient decision making based on knowledge• The organization can use its full knowledge in all

situations• Expert knowledge brought to the fingertips of the

operators

The key benefits:

• Comprehensive process history• Flexible user tools for reporting and analysis

• Scalable from long-term trending to data warehousin

• Open to all data accessed using industry standard

• Interfaces, such as ODBC and ADO

maxDNA provides the power plant builder, owner and

operator with a comprehensive data warehousing solu-

tion for all process and product related information.

Composed of historians, for continuous and alarm

histories, this data warehouse forms a solid basis for a

diversity of user tools.

The sophisticated DNAuser tools include, for instance, the

DNAparameterEntry-user tool, which is utilized to enterconstant values and parameters; the DNAruntime, which

is a runtime monitoring tool used to record running times

and start-ups; and the DNAreplay, which is a tool utilized

to replay past events. The Alarm Historian allows the

operator to search and sort alarms.The advance browsing

features assist in finding the cause of a disturbance (alarm)

and help in predicting and avoiding similar problems in

the future.

The maxDNA information management activity combines

the results of information analysis and a user ’s experience

to create an or

ganizational memory and shared experi-

ence. Combining history and real-time process data pro-

vides knowledge that strengthens decision-making in

disturbance management.

The DNAproCalc calculation environment includes auto-

matic database operations, standard calculation proce-

dures and thermodynamic library functions.

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Software and hardware licenses

History database licensesDNAhistorianDNAhistorian capacity,license/tag

User Tool licensesDNAprocessExplorer,license/client PCDNAsummary,license/client PCDNAruntime,license/client PCDNAtotal,license/client PCDNAreplay,license/client PCDNAlogReport,license/clie nt PCDNAhistoryODBC,l icense/client PCDNAtrend@web,license/client PCDNAbatchReportDNAcalcDNAmultivariateDNAspc

DNAproCalc license

Hardware for historiansWindows NT

Hardware for User ToolsWindows NT PC



Advanced Controls

The application engineers of Metso Automation MAX

Controls are state of the art in process automation for

the utility industry. They are familiar with all types of

boilers, including Alstom Combustion Engineering,

Babcock & Wilcox, Mitsubishi Heavy Industries, Foster

Wheeler and Riley Stoker. The expertise extends to all

furnace types, from tangentially and front and rear-

fired furnaces to down-shot furnaces, fluidized bed

boilers and once-through boilers.

Metso Automation has unique control strategies for multi-

ple-fueled boilers,ball mills,an d coordinated boiler-turbine

control.The unique D-E-B coordinated control strategy is

used around the world on all types of units and is consid-

ered the standard against which all others are measured.

Over 250,000 MW of generating capacity are being con-

trolled by MAX1,MAX1000,and maxDNA systems.

Metso Automation has designed and delivered systems

ranging from small industrial applications to units as large

Operations – eyes on the process

maxSTATIONs are the eyes and ears to the process.

They are commercial or industrial-grade Pentium-

based PC’s running onWindows NT. maxVUE software

provides the operators with the ability to view and con-

trol the process, through a series of user-specified or

built-in screen graphic displays that mimic portions of

the plant process.maxVUE advises operators of abnor-

mal process conditions through the flexible but com-

prehensive alarm management function.The maxSTA-TIONs, depending on the user access level, can use the

graphical configuration and graphics editor to create

new dynamic displays,configure control strategies and

download database information to the system DPUs.

The maxSTORIAN is an integrated software module that al-

lows the maxDNA user to collect, manage and retrieve his-

torical information about the operation of the process.The

maxSTORIAN plugs into the Software Backplane, where

acquires real-time information on a subscription basis an

archives it in a retrievable format. It presents informatio

in the form of reports and trends, usable by operators an

others within and outside the plant.It uses a delta-save com

pression algorithm to maximize the amount of informatio

archived.For higher reliability storage requirements, it ca

also be used with redundant disk arrays.The maxSTORIA

can collect alarm events, operator actions and processevents time tagged to one millisecond, in addition to co

lecting selected system wide process variables.

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as 1000 MW.Metso Automat ion systems, with over 40,000

tagged points,now operate on coal-fired generating units

in excess of 500 MW. In addition, Metso Automation has

supplied systems for large combined-cycle plants, as large

as 1000 MW that have over 25,000 tagged points. These

integrated total plant control systems include coordinated

control,burner management,automatic startup and shut-

down, and plant monitoring.

The goal of Metso is to continue to serve the electric

power industry. It also serves other important markets,

such as the glass processing industry, where its systems

are used in all the functions of the plant, from the raw

product mixing, tight temperature and level control in the

fore hearth and conditioning channels, to the annealing

lehr and glass cutting operations. Some of the largest

glass lines in the world are controlled by Metso Automation

systems.



Reliable architecture

maxDNA is the result of two decades of evolutionaryprocess automation advancement. It continues to pre-serve your plant automation investment by being100% compatible with the first MAX1 shipped andeach legacy system in between. maxDNA offers usersthe ability to expand and upgrade, with a clear path tothe future. This is accomplished by blending the lead-ing operating systems, Windows NT and Windows CE,with high-speed switched Ethernet (maxNET) commu-nications and our own world class Distributed Process-ing Units (DPUs), to give you an open and reliable con-trol system. maxDNA includes robust controlalgorithms proven in power generating stations andprocess plants throughout the world.

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Starting with a fast, switched Ethernet TCP/IP connectionat 100megabits per second as the maxNET backbone,Metso Automation selected intelligent switches, insteadof repeaters, to eliminate communication collisions. Thisresults in a deterministic communication network thatdoes not waste communication time and bandwidth onerror recovery. It eliminates errors. Metso Automationthen made the network redundant to improve reliability,and full duplex to increase throughput.

maxNET connects all of the DPUs to each other via switch-

es,and links the maxSTATIONs used by operators,engineers

and managers into a high-speed, reliable and well-

integrated system.As a result, the system is easy to connect

to with other devices, such as PLCs or personal computers

used by business or process analysts, both within and

outside the plant. Peer-to-peer communication between

any devices on maxNET is easily accomplished, without

any cumbersome receive algorithms.

Dynamic security and reliability features continuously

monitor and protect maxNET from any network intrusions.

maxNET will quickly reject excessive or unwanted traffic,

such as broadcast storms. This is very important in an

open Ethernet system that is designed to be accessible

by people throughout the organization .maxN ET supports

real-time redundancy of networks and does not wait for

extensive TCP/IP timeouts before making use of alternate

network channels. For added security or to prevent un-

wanted interaction between network connections, max-

NET can be segmented into domains. maxNET supports

remote access and utilizes policy files to enforce user-

defined restrictions which prevent unwanted access to

the system.

maxDNA incorporates a unique approach called Software

Backplane, which brings ‘Plug-and-Play’ to system-wide

information sharing.It allows information obtained by the

system, from local and remote I/O, data links to other

devices, or output variables from control strategies, to b

easily shared by other software applications and devic

connected anywhere within the system.

maxLINKS is a secure interface between maxDNA and

external devices not produced by Metso Automation MA

Controls. This represents a wide and heterogeneous m

of equipment, ranging from machinery control sub-systems, often implemented with PLC’s such as soot blow

ers or burner management systems, to specific devices

e.g.turbine controls or chemical analysis instrumentatio

needed in water treatment. It includes existing popula

PLC and turbine control communication protocols and

point configuration editor. A maxLINK communication

channel can be configured as a simple, bi-directional

duplex or dual redundant channel based on the type an

importance of the information being transported over

the link. It can transport information for up to 10,000

unique data points over a single channel or over up to

sixteen channels.Depending on the number of data poin

being processed and the frequency of processing, max

LINKs can reside within an existing maxSTATION. For hig

traffic communications it may require a separate Window

NT based workstation. If a dual communication channe

is required to satisfy the reliability of the transmitted

information, two separate NT-based workstations may b

required.

The Software Backplane provides each software application with a ’ Plug-and-Play ’ access to the system-wide data point information.

Knowledge Management

InformationManagement

Operations Engineering andMaintenance

m axOP C m axST OR IA N AlarmProcessing

maxSTATIONmaxVUE

maxVUE editor maxTOOLSGraphical Configurator

Connectivity

maxLINKSExternalInterfaces:

• Computers• Logic systems• Measuring devices

Controls

maxDPU4E

eDNA

Cyber ConnectionsCyber Services

Field

Local maxPACRemote maxPAC, Bus Extended

OfficeNetwork

maxNET

Processnet

Fieldbuses

SOFTWARE BACKPLANE

maxVUE maxAPPS maxCALCS maxLINKS

maxTOOLS maxOPC maxSTORIAN metsoDNATOOLS



DPUs – always in control

DPUs are the process brains of the system. They are mul-

tifunctional controllers and data acquisition processors

that execute control algorithms, run sequence logic and

time tag events to one millisecond resolution. They are

Pentium based and run on the Windows CE operating

system. DPUs contain a complete on-board database of

the graphical interconnection of the installed logic.

What you see on the graphical configuration is what is

installed within the DPUs. It is impossible to be viewingthe incorrect logic.

To help plant engineers test newly created control algo-

rithms and strategies,and make tuning adjustments before

putting them on line, we have developed the Virtual DPU,

which can be configured within any maxSTATION as a

simulation test-bed. The user can connect real process

inputs to the newly developed strategy and examine the

control results in real time, or over some time period by

reviewing the history files.Virtual DPUs can be permanent-

ly installed as an operator-training tool, or as an environ-

ment for special calculated points, alarms and events.

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DPUs are connected to your plant’s process sensors and

controllable end-element devices through I/O cards that

filter transients, convert analog signals to digital values,

read the condition of two-state devices,and provide output

commands to regulating valves and air damper drive units.

DPUs and their related process I/O do not have to be

centrally located. They can be located near the devices

they are controlling, thereby providing a geographically

distributed control system within your plant. DPUs aretypically set up as a redundant active/inactive configura-

tion and can be configured to have redundant I/O cards

if needed. DPUs are connected directly to the maxNET

communication network.There are no intervening servers

to slow down data transfers or introduce points of failure.

DPUs are hardened against denial of service attacks, inad-

vertent or intentional. In other words, DPUs control the

process and intelligently manage information flow be-

tween all connected devices.

Control room equipment

Operator’s maxStations• Pentium,128 MB RAM,hard disk, CD-ROM,2 network cards,

keyboard,track ball,Windows NT

Engineer’s maxStation• Pentium,256 MB RAM,hard disk, CD-ROM,3 network cards,

keyboard,track ball,Windows NT

maxStorian• Pentium,512 MB RAM,SCSI hard disk,CD-ROM,3 Network

cards,keyboard,track ball,Windows NT

maxLinks• Pentium,128 MB RAM,hard disk, CD-ROM,3 network cards,

multi-channel Rocket port,keyboard,track ball,WindowsNT

Monitors and keyboards• Standard PC monitors 17”-22”

• Flat screens• Dedicated operator’s keyboard• Track ball or mouse

Large screen devices• Rear projection screens 40” to 158”

Printers• Network B/W laser report printer• Network color laser screen printer• Network B/W dot matrix continuous form alarm printers

Hardware

Geographically distributed components

maxNet components• Multiport 100/10 Ethernet switches• Electrical to fiber optic adapters

maxDPU4E• Pentium based,Windows CE,32 MB RAM, non-volatile flash

memory, 2 maxNET ports,2 serial ports,Software Backplaneinterface,time synchronization to IRIG-B or stable time card,1 mS SOE, 564 I/O form factor.

maxPAC I/O• Family of high-density I/O modules,chassis,and cables for

connecting the maxDNA Plant Automation System to theprocess sensors and controllable output devices.

• IOP301 isolated analog input 4-20mA,16 channel• IOP302 non-Isolated analog input 4-20mA,16 channels• IOP303 3-wire RTD input,8 channels• IOP304 thermocouple analog input,16 channels• IOP305 analog input 0-2.4Vdc,16 channels• IOP320 analog output 4-20mA,8 channels

• IOP330 non-isolated digital input 24Vdc,16 channels• IOP334 isolated digital input 24Vdc,16 channels• IOP331 non-isolated digital input 48Vdc,16 channels• IOP332 isolated digital input 120Vac/Vdc,16 channel• IOP333 isolated digital input 240Vac/Vdc,16 channels• IOP350 digital output,form“C” relay contact,3A @ 30Vdc,

10 channels• IOP351 digital output,form“A/B” relay,3A @ 30Vdc,

16 channels

Environmental specifications

Temperature (Fahrenheit)

• PCs 40-122• Printers 50-95• Monitors 41-95• Keyboards & mouse 41-95• Operator keyboard (IP65) 32-131• maxDPU4E’s 0-140• maxPAC I/O 0-140

Relative humidity (percent non-condensing)• PCs 20-95• Printers 20-90• Monitors 10-90• Keyboard & mouse 20-95• maxDPU4E’s 5-90• maxPAC I/O 5-90

Other environmental specification pertaining tomaxPAC I/O and DPU4E’s• EDS IEC 801-2• Electrical surge IEEE-472-1974 SWC• RFI IEC 801-2 with cabinet door closed• Vibration Sinusoidal vibration specification per SAMA PMC

31.1 using control room level; 1mm displacement 5-15Hz,0.5G 15-150Hz.

• IOP381 4 pack maxPAC rack • IOP382 8 pack maxPAC rack • IOP383 6 pack maxPAC rack



Life-long service

Customer care begins in the early stages of your

project and follows through long after your system is

installed. At contract award, the Metso Automation

team of project and system engineers works with you

to build a robust system that satisfies your technical

specification and accommodates any new informa-

tion. For easy recognition, data from system-

monitored points and from other automation sys-

tems are organized by process area and function. TheMetso Automation graphics display analyst assists

you with the layout of CRT screen displays, to give you

an uncluttered view of critical information that is eas-

ily comprehended by your operating people, even

under the most stressful alarm conditions.

Metso Automation trainers instruct your operating peo-

ple on how to use the system for plant control and how

to maintain it, including the creation of new displays and

new software applications. When fully trained your oper-

Proven solutions

The family of Metso Automation products has been

solving monitoring and control problems for over 20

years, and on over 10,000 projects worldwide. Metso

Automation offers systems ranging from hardware-

only systems, with configuration engineering by our

customers or system integrators, to fully i ntegrated

and engineered systems that include all equipment

within the control island package.

Nearly 90% of the MAX1 systems installed are still in ser-

vice and provide the same precise control and ultra-high

reliability envisioned by their purchasers some 15 to 20

years ago. Parts replacement has averaged less than

0.0163%, providing the absolute lowest life-cycle cost of

any plant automation system. With the multi-featured

ProcessPerformance

PerformanceAudits

TechnologyRenewal

ProcessOptimization

ProcessUptime

CorrectiveMaintenance

PreventiveMaintenance

PredictiveMaintenance

ProcessImplementation

Installation

Services

Start-upServices

InstalledBase

Services

New ProcessSolutions

Measurements& Control

Applications

Information& Automation

Systems

Technology& KnowledgeManagement

O p p

o r t u n i t i e

s

N e w B

u s i n

e s s

14

ators’ reactions become instinctive, shortening reaction

time and improving decision-making.

When your system is ready for factory-acceptance test-

ing, Metso Automation’s field commissioning engineers

will work along side you during the test, to help prepare

for a smooth system installation and startup. The com-

missioning engineers help to install, start up the system,

and re-run the factory test, to assure nothing was dis-turbed during the shipment of the system. They will help

with a point-by-point, end-to-end checkout to assure

that each input and output is correctly wired. They will re-

view your spare parts inventory and suggest possible

stocking level changes based on your system size. They

will train your staff to maintain the system or, if you prefer,

they will offer a preventative maintenance program that

will keep your system at peak performance without in-

creasing your maintenance staff.

Our service specialists are the human link in the chain of high-tech support

that connects you and us. Using the latest communications technologies,our best specialists are always close to you and your maxDNA network.

maxDNA system, legacy systems can continue to per-

form flawlessly while joining the Information Age via

Metso Automation’s unique Migration Process, which i

the fastest, most cost-effective upgrade path available t

users of any plant automation system. Automation too

provide a complete and worry-free upgrade, which in

some cases can be implemented on line or over a wee

end mini-outage.

Yearly ISO9001 re-certification is routinely achieved no

only by our manufacturing group but by all facets of th

Metso Automation organization, thereby guaranteeingevery customer the ultimate in quality and satisfaction

Want To Learn More?

To find out more about the maxDNA system, ask a Met

Automation sales or application engineer to discuss ho

we can improve your plant’s performance. Or log onto

our website at www.metsoautomation.com.

maxdna_technologydcs

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