FORM 2
THE PATENTS ACT, 1970
(39 of l970)
&
PATENTS RULES, 2003
(COMPLETE SPECIFICATION)
TITLE OF INVENTION - "A TESTING KIT FOR DIGITAL CONTROL SYSTEM (DCS) CARDS, AND METHOD OF TESTING, USING THE SAME."
NAME OF APPLICANT - "RELIANCE INFRASTRUCTURE LIMITED"
ADDRESS OF APPLICANT - RELIANCE INFRASTRUCTURE LIMITED
DHANU THERMAL POWER STATION, DAHANU ROAD, THANE 401 608, INDIA
The following specification particularly describes the nature of the invention and the manner in which it is to be performed.

FIELD OF THE INVENTION:-
A testing kit for Digital control system (DCS) cards, and method of testing, using the same.
FIELD OF THE INVENTION:-
The present invention generally relates to the state of art industrial control systems, and more specifically to testing of distributed digital control system cards. This includes testing of modules in integration with field instruments with multiple stored databases and specifically for controlling the any process in the Thermal/hydro - Power Station.
PRIOR ART:-
US patent no. 6185466, A distributed digital control system includes a plurality of control modules which are interconnected by a communication link. Each module includes a processor unit for running a control program, and a plurality of system databases which correspond to nodes in the system. Each module further includes a selector such as a Dual Inline Package (DIP) switch for inputting a node number. The program automatically selects the database corresponding to the input node number when the module is powered up. The system preferably utilizes the industry standard protocol, with each database including Standard Network Variable Types (SNVTs) and Standard Configuration Parameter Types (SCPTs) for the respective node. A default database is also stored in each module, which is automatically used by the program if the system databases are not found.
US patent no. 8462796; A distributed digital control system embodying the present invention is commercially available from Proteus Industries, Inc., of Mountain View, Calif, the assignee of the present invention, under the product name Fluid Talk. The system measures the flow rate, temperature and pressure of liquid in industrial equipment cooling systems. However, the present invention is not limited to cooling system control or any other particular application, and can be adapted to any environment in which distributed digital control is required is interlinked with any field instruments.
CN202306296U
The utility model belongs to the technical field of simulated energy control for servo mechanisms, in particular to a distributed type digital control servo energy system, and aims to perform the function of remotely controlling a ground energy system. The distributed type digital control servo energy system consists of a simulated energy cabinet, a simulated energy control box and a variable-frequency power source, wherein the simulated energy control box comprises a touch screen MP377, a programmable logic controller (PLC) master station and an emergency shut-down switch component; the simulated energy cabinet comprises a remote input/output (I/O) ET200M slave station; the variable-frequency power source comprises a remote I/O ET200M slave station, and a DP two-stage Schneider ATV71 frequency converter equipped with

a PROFIBUS-DP communication adapter; and the simulated energy control box communicates with and controls the remove I/O ET200M slave station in the simulated energy cabinet, the remote I/O ET200M slave station in the variable-frequency power source, and the DP two-stage Schneider ATV71 frequency converter equipped with the PROFIBUS-DP communication adapter through a PROFIBUS-DP bus. The expansibility is strong, the reliability is high, the market application prospect is good, and the automation testing level of a hydraulic system can be effectively increased.
EP0575145B1
An open network system includes a network and modules connected thereto, one of said modules being an operator station, each module including an internal bus operatively connected to the network, a module central processing unit (CPU), and a module memory, both being coupled to the internal bus. An interface to at least one foreign system allows display information from the foreign systems and from the network system to be displayed. A processor receives display information from the foreign system and also provides control information for the display unit. A graphics element connected to the processor and to the internal bus generates formatted display information from that received from the processor and the internal bus in response to the control information from the processor.
OBJECT OF THE INVENTION;-
The object of the invention is testing the cards and identification of faulty cards. The facility is incorporated to connect and operate all type of field instruments and devices such as relays, RTD, thermocouple, transmitters and actuators etc.,
Further object of the present invention is that features are incorporated for signal simulation, history recording is unique the field of the digital control system,
Important object of the present invention is by Facility of prototype of MCC, added for Testing of Electrical Actuators, which is also applicable to any other field instruments in power plants
Further important object of the present invention is that with a simulator type approach adopted, the testing can be carried out as in actual operating environment.
Very import object of the present invention is that with provision to connect the Electrical & Pneumatic actuator to this kit in the laboratory, to evaluate the response and study the problems prior to installation at site, followed by validating the effectiveness of logic changes before employing to online system.

Further important object of the present invention is that the Provision for testing and observing repaired electronic hardware, is incorporated in the system,
SUMMARY OF THE INVENTION:-
The control system is based on Pro-control -P13/42, DCS covering entire process streams pertaining to main plant. DCS digital control system is directly interfaced with Human Machine Interface for operator controls, which has potential to control and monitor the process to the extent of 100 percent.
In DCS various logics for interlocks/protection are buildup to run the process most effectively and safely. There are total approximately 6900 electronic cards and 30000 signals.
In process industry safe, reliable and stable operation of the system is essential. To ensure smooth running of the process, various field inputs are processed at very fast rate in electronic cards of Distributed Control System (DCS) like processor and Drive control Modules and commands are issued , These electronic cards are the backbone of reliable operation as they handle logics of the all critical & non-critical processes in hardware & software form. It becomes imperative at this juncture to point out that failure of Electronic cards may lead to unreliable process which may causes partial loading or costly unit tripping. At times it may directly affect the safety of Process equipments & personals.
DESCRIPTION OF THE INVENTION:-
The present invention describes about a testing kit for testing digital control system cards, Controller, various field instruments, systems for power plant, hydropower plant, and its field instruments. This kit is used for the testing of card in one attempt or multiple cards in the same. The said cards testing kit is designed for testing cards of distributed digital systems, Pro control P13/42, along with field instruments.
The said kit containing the features of modular electronics of pro control PI 3 /42 which being used for testing various tasks.

This kit comprising a frame designed in manner to adapt various cards of DCS Pro control P-13, rack. It has two numbers of racks, the frame size can be selected as per requirement. Various components which are required for testing different cards and its testing comprises the pro-control rack (1), with back slots (2), MCB power supplier ( 3) also incorporated for supply of power to the pro control 13. Further not limited to this but the present invention describes particularly for testing the cards. Those cards are arranged in the rack in accordance with their corresponding wiring in the system, as the wiring has to be made to operate particular field instrument. The input connections required for the card are mounted on a Bakelite plate (4). In order to construct the kit, the wiring is done form the input connection to the decided card location, LED (6) or lamps are mounted for testing the output cards same are also wired up to recorder/indicator for history The testing can be done based on the input provided initially and the expected output according to input, if the desired result is not obtained, then it is to be concluded that the particular cards has failed.
The cards can be classified with suitable wiring for particular field instrument; the cards being incorporated in the PRO-CONTROL PI 3 / 42 are as follows
► Modular electronics: dedicated for various tasks
► Redundancy: Processor, Bus, Power supply
► Flexible in configuration
► High electrical noise immunity.
► Self diagnostic capability
SUB SYSTEMS of DDC PROCONTROL P13/42
► Measurement system.
► Local bus P13
► Intra-plant bus P42
► HMI (Human Machine Interface)
► Control system (sequence, close loop control system)

MEASUREMENT SYSTEM
The measurement system accepts following inputs / output
► Analog Input (4 TO 20 ma) - ( Pressure, Level, Flow)
► RTD Input (Ohm)
► THERMOCOUPLE Input (mille volt)
► BINARY Input (Limit Switch, Push button, Pressure Switch)
P13 LOCAL BUS
► Local bus 70BL01 is aPCB
► 70 BL02 : Connecting cable
► Connects Input / Output modules, Processor, Interface Module
► Transmits signals in serial mode to the modules
► Controlled by Bus traffic director (BV05).
► Capacity of 256 addresses (00 to FF Hexa decimal).
► Bus traffic director calls out addresses sequentially from 00 to FF
P42 INTRAPLANT BUS (IPB)
► Data exchange between the local buses via Intra plant bus
► Coaxial cable "looped" through the various local buses.
► Consists of Address transmitter (70FV01) and the coaxial cable.


The kit is developed using spare racks of Pro-control P13, slot wiring of different types of cards and providing interface for connecting various field devices. All the features are provided through in-house engineering and now the kit has become indispensible after realizing the benefits and utility. OEM letter of appreciation and various awards has aggrandized the utility of the Kit.
♦ Schedule of activities
Frame prepared from workshop according to the dimension of the Pro-control racks with
mounting arrangement
Power supply with Protection arrangement made in the rack
Bakelite plate prepared with jacks mounted for input signals
Mounting arrangement for mounting Lamps for connecting Outputs
Wiring done as per the card details and slot identified
Programming of spare chips for drive and processor modules
Recorder configuration done and connected to the out put card
Trial taken with different type cards and outputs monitored.

♦ Prominent Features


Facility is incorporated to connect and operate all type of field instruments and devices
i.e. Relays. RTD, thermocouple, transmitters. On the frame itself in order to identify the
entire feature, clearly.
Features incorporated for signal simulation, history recording.
Facility added for Testing of Electrical Actuators with a prototype of MCC
A simulator type approach adopted so that testing can be carried out as in actual
operating environment.
Provision to connect the Electrical & Pneumatic actuator to this kit in the laboratory to
evaluate the response and study the problems prior to installation at site.
Facility to validate the effectiveness of logic changes before employing to online system.
Provision for testing and observing repaired electronic hardware.
Facility added for Data Logger to identify passing faults
Suspected faulty modules from the system can be subjected to intensive diagnostic test in
the test kit.
Testing facility for complex modules like drives and processors.

In the further embodiment of the present intention is that the following cards are arranged on the rack, the cards required to be tested correspondingly to its feature as specified in the table below
In the existing System, Malfunction of auto control loops noticed without any visible reasons. Lack of facility to check the healthiness of DCS cards before inserting into online system is also a major concern. There was no such provision to check response of process instruments with their input & output cards. Passing faults cannot recognize in existing system. One of the major problems faced also is inadequate resources for testing new or modified logics prior to implementation.

In present system, facility incorporated such as to connect and operate all type of field instrument and devices i.e. Relays, RTD, thermocouple, transmitters etc. Also history recording is possible for any passing faults. There is provision to connect the Electrical & Pneumatic actuator to this kit in the laboratory to evaluate the response and study the problems prior to installation at site.
Validation of in-house developed logic before employing to online system. Also there is provision to test & observed response of repaired electronic hardware. Apart from these, suspected faulty modules from the system can be subjected to intensive diagnostic test in the test kit & testing facility for complex modules like drives and processors.
Advantages of the Product/ Process / Concept / Invention:
New / Repaired cards are tested prior to installation into process.
The kit has facilitated the in house repairs of multilayer modules.
Reduction in inventory by utilization of repaired cards in the process.
Integrated Card testing possible along with field sensors to identify problems and
studying response.
Developments made in the kit have alleviated testing with response history to find out
passing faults.
Exact identification of defect helped OEM in repairing of Cards. This avoided repeated
repairs. ,
Utilized as training Simulator to train all executives, trainees, Vocational trainees.

We Claim,
1. A testing kit for testing digital control system cards, of various field instruments, of the power plant, for one or multiple cards comprising,
a) A pro control P13 and 14 microprocessor based system, is being specifically designed for testing the cards
b) The said pro control PI3 and 42 containing the features of modular electronics used for testing various field instrument tasks, comprising a frame designed to adapt cards, wherein the frame size is being selected in any desired size to adapt cards, the different cards and its testing characterized in that the pro-control rack (1), with back slots (2) are arranged on each other, a MCB power supplier (3) assembled for supply of power to the pro control 13, back light plate (4). In order to construct the kit the wiring is done form the imput connection to the decided card location, LED (6) or lamps are mounted for testing output and same are wired to the respective cards and its location indicator / recorder (7) are wired upto location of the output cards, those cards are arranged in the rack in accordance with their corresponding wiring in the system, in order to operate particular field instrument,
2. A testing kit as claimed in claim 1, wherein the, testing can be done by introducing input parameter initially followed by expected output parameter, wherein the cards are selected from
► Modular electronics : dedicated for various tasks
► Redundancy: Processor, Bus, Power supply
► Flexible in configuration
► High electrical noise immunity.
► Self diagnostic capability

P13 LOCAL BUS
► Local bus 70BL01 is a PCB
► 70 BL02 : Connecting cable
► Connects Input / Output modules, Processor ,Interface Module
► Transmits signals in serial mode to the modules
► Controlled by Bus traffic director (BV05).
► Capacity of 256 addresses (00 H to FF H).
► Bus traffic director calls out addresses sequentially from 00 to FF in 40 msec
3. A kit as claimed in claim 1 and 2, wherein the slot wiring of different types of cards and providing interface for connecting various field devices,

4. A kit for testing cards as claimed in claim 1, wherein the cards are selected as,

ARD TYPE DESCRIPTION CARD TYPE DESCRIPTION
BA01 BUS TERMINATION MODULE PR05 PROCESSOR MODULE FOR PRO-CONTROL
BK03 BUS COUPLER SERIAL INTRFACE MODULE SL05 TEST MODULE FOR SIGNALS
BV05 BUS TRAFFIC DIRECTOR ST01 TEST MODULE FOR DRIVES
EAOl CARD ANALOG INPUT + / - 20 Ma/lOV DD370 DIODE MODULE
EA02 CARD ANALOG INPUT FOR 2 WIRETRX UA374 SIGNAL DISTRIBUTION MODULE
EA03 ANALOG INPUT FOR RTD ABO I OUTPUT MODULE BINARY 24V
EA04 ANALOG I/P FOR THERMOCOUPLE AB02 OUTUT MODULE WITH POTENTIAL FREE
EB01 BINARY INPUT FOR 24 V AS04 DRIVE CONTROL ON-OFF MODULE
EB02 BINARY I/P SUPERVISION MOD. AS06 DRIVE CONTROL MODULE -MODULETING-
EB03 BINARY INPUT CI W SUPERVISION AA01 ANALOG OUTPUT FOR VOLTAGE SIGNA
AA02 ANALOG OUPUT FOR CURRENT SIGNAL