This article introduces the basic components and characteristics of industrial control configuration software, and elaborates on how to build a monitoring system using configuration software in conjunction with a practical engineering project. 1. Introduction The term "configuration" originates from the English word "Configuration." As a professional term, "configuration software" currently lacks a unified definition. In essence, configuration software refers to the process by which operators configure (including defining, creating, and editing objects, and setting object state characteristic attribute parameters) user application software according to the requirements of the application object and control task. In other words, configuration software can be viewed as an "application generator." From an application perspective, configuration software is a software platform that facilitates communication between system hardware and software, and establishes a human-machine interface for communication between the field and the monitoring layer. Its application is not limited to industrial automation. Industrial control is a crucial application area for configuration software. With the emergence of Distributed Control Systems (DCS), configuration software has been introduced into industrial control systems. There are two main categories of variable factors in industrial process control systems: changes in operator requirements and changes in the state of the controlled object and the hardware used by the controlled object. Configuration software, while keeping the software platform's executable code unchanged, adapts to the requirements of two different systems on two key factors by modifying software configuration information (including graphical files, hardware configuration files, real-time databases, etc.), thus building a new monitoring system platform software. This approach to system construction improves system integration speed, ensures software maturity and reliability, and provides convenient and flexible use, as well as ease of modification and maintenance. [img=400,145]http://www.cechinamag.com/images/Article/4f716c00-1845-4bb6-8388-cb991cd9a3dd/11.gif[/img][align=center] Figure 1[/align] 2. Composition and Characteristics of Industrial Control Configuration Software 2.1 Composition of Industrial Control Configuration Software Whether it's Intouch, the world's first industrial control configuration software launched by Wonderware in the United States, or various configuration software today, from an overall structural perspective, it generally consists of two main parts: the system development environment (or configuration environment) and the system runtime environment. The system development environment is the working environment that automation engineers must rely on to implement their control schemes and generate application programs with the support of configuration software. It generates the final graphical target application system by creating a series of user data files for use in the system runtime environment. The system runtime environment loads the target application program into computer memory and puts it into real-time operation; it is directly used for on-site operation. The link between the system development environment and the system operating environment is the real-time database, and the relationship between the three is shown in Figure 2. [img=400,153]http://www.cechinamag.com/images/Article/4f716c00-1845-4bb6-8388-cb991cd9a3dd/12.gif[/img][align=center] Figure 2[/align] 2.2 Features of RSView32 Configuration Software Rockwell RSView32 industrial control configuration software is a configuration software produced by Rockwell Automation in the United States. It is an HMI (Human Machine Interface) software package based on MFC (Microsoft Foundation Classes) and COM (Component Object Model) technologies, running under the Microsoft Windows 9X/Windows NT environment. Its main functions can be analyzed from the following aspects: Comprehensive configuration software with diverse functions Rockwell RSView32 configuration software provides an industrial standard mathematical model library and control function library, with flexible configuration modes to meet the measurement and control requirements of users. RSView32 stores, displays, calculates, analyzes, and prints historical data of measurement and control information. Its interface is flexible and convenient, featuring a dual security system for reliable data processing. Rich display configuration functions: Rockwell RSView32 configuration software provides users with a wealth of convenient and commonly used editing and drawing tools, offering numerous industrial equipment and instrument symbols, as well as trend charts, historical curves, and group data analysis charts. It provides a highly user-friendly graphical user interface (GUI), including a complete set of Windows-style windows, pop-up menus, buttons, message areas, toolbars, scroll bars, and monitoring screens. The rich and varied displays greatly facilitate the normal operation of equipment and centralized monitoring by operators. Powerful communication capabilities and excellent openness: Rockwell RSView32 configuration software can communicate downwards with data acquisition hardware via Winteligent LINK, OPC, OFS, etc., and upwards with higher-level management networks via TCP/IP and Ethernet. For DDE or OPC data sources, a list of "tag/value" pairs is transmitted to the DDE or OPC server and client (server/client). Write operations on the server may be combined in the information packet (depending on the server's execution). A Browse OPC Server Space OPC address browser has been added to the database editor for easy connection to OPC data sources. The Rockwell RSView32 configuration software, based on Windows 95, Windows 98, and Windows NT, provides a multi-tasking software runtime environment, database management, and resource sharing. It fully utilizes object-oriented technology and ActiveX dynamic link library technology, greatly enriching the control system's display screen and programming environment, thus facilitating flexible multi-tasking operations. An ActiveX object is a ready-made software component developed by a third-party vendor. RSView32 can use its provided functionality through its properties, events, and methods. By embedding an ActiveX object and setting its properties or specifying object events, the object can interact with RSView32. Information is passed between ActiveX objects and RSView32 via RSView32 tags. Windows provides an interface between RSView32 and Windows-based applications, such as DDE (Dynamic Data Exchange) technology, for data exchange with Windows applications. This enables data and information sharing between the local control unit and the host computer, providing users with a more centralized data operation environment, enabling centralized information management, and providing an open database interface (ODBC) to upper-level systems. RSView32 supports the following ODBC-compatible databases: MS Access, Sybase SOL Server, Oracle, and MS SOL Server. Data is stored in ODBC format using ODBC data sources such as Microsoft Access or Microsoft SOL Server. ODBC format storage stores data in up to three tables. It can use the command Activity Logsend To Odbc to send activity log data from a .DBF file to an ODBC-compatible database. If the receiving database is incompatible with ODBC, output will fail. If the table bridge does not exist, RSView32 will create it. Additionally, RSView32 adds a new object, ODBC Administrator. This object provides methods for creating and inspecting tables for ODBC data records. 3. Application of Industrial Control Configuration Software in Auxiliary Monitoring Systems of Thermal Power Plants The peripheral systems of a power plant are an important part of the plant's production and operation management. However, compared with the boiler and turbine control, their operation is relatively simple, and they are basically controlled independently on-site. 1) The personnel required for operation are large, resulting in high costs; 2) Due to their dispersed locations and distance from the central control room, the operation, maintenance, and management of the system face many difficulties. Therefore, adopting advanced network control technology to achieve centralized control of all peripheral systems can not only solve many problems in system design and equipment, but also create a good foundation for building a unified enterprise network and achieving integrated management and control. The following is an example of our implementation plan in the centralized monitoring system of peripheral equipment in a power plant in Shandong Province, which introduces the construction of a centralized monitoring system for auxiliary equipment using Rsview configuration software. Practice has proven that this solution has achieved good results from design to implementation. 3.1 System Composition Before Modification 1) Chemical Makeup Water Control System (One set for 4×300MW) This system uses the SCHNEIDER MODICON QUANTUM series PLC and the Modbus plus industrial network fieldbus as the host computer monitoring system. 2) Condensate polishing control system for Units #1 and #2 (one set for 4×300MW): This system uses AB's PLC/5 series PLC and DH+ network as the network communication method for the monitoring system. Two host computers are set up for monitoring. 3) Condensate polishing control system for Units #3 and #4 (one set for 4×300MW): This system uses AB's Conlogix series controller and ControlNet fieldbus network as the network communication method for the monitoring system. Two host computers are set up for monitoring, and it is located in the same main control room as Units #1 and #2. 4) Steam and water sampling and dosing system for Units #1, #2, #3, and #4 (two sets for 4×300MW): This system uses an A/D communication card installed in the industrial control computer to monitor the field sampling signals. Each variable frequency pump in the dosing system is independently controlled by a local microcontroller. Furthermore, the systems for Units #1 and #2 are located in different locations from those for Units #3 and #4. The system distribution diagram is as follows: [img=400,99]http://www.cechinamag.com/images/Article/4f716c00-1845-4bb6-8388-cb991cd9a3dd/13.gif[/img][align=center] Figure 3[/align] 3.2 Implementation Plan Based on the geographical distribution and comprehensive consideration of the plant requirements, it was finally agreed that the central control room would be located in the chemical makeup water control room. Based on the current system status, a phased renovation plan was adopted. Step 1: Given that the chemical makeup water control system and the central control room are located in the same room, AB's dedicated protocol conversion communication card and supporting software MB+ OPC Server were used to complete the MB+ protocol conversion and communication with the upper computer configuration software RSView. This card is in PCI bus form and is directly plugged into two servers, which then connect it to the entire Ethernet network. The servers used are IBM Xserver. [img=400,264]http://www.cechinamag.com/images/Article/4f716c00-1845-4bb6-8388-cb991cd9a3dd/14.gif[/img][align=center] Figure 4[/align] Step 2: Based on the composition of a typical switched Ethernet control network, two CISCO 24-port 100M switches are installed in the network cabinet of the central control room to complete Ethernet data exchange. 3COM 100M industrial Ethernet cards are installed in the server and operator station. An APC UPS power supply is also provided. Step 3: Since this system involves multiple fieldbuses such as DH+, MB+, and ControlNet, a ControlLogix Gateway is required to complete the protocol conversion. This gateway should have the following capabilities: 1. Receive data from each fieldbus segment, interpret it, convert it into a format that Ethernet can receive, and transmit it to the switch; 2. Convert the commands and data issued by the system into the data format of each fieldbus segment and transmit it downwards. Therefore, considering the geographical location, it was decided to install a gateway in the condensate polishing control room. This gateway is equipped with DH+ modules, ControlNet modules, and Ethernet modules. Fourth step: Due to the long distance (approximately 1km) between the gateway and the switch, and considering the real-time nature and interference resistance of data exchange, it was decided to use fiber optic communication between the two, with redundancy and mutual backup. Fifth step: Redesign of the steam and water sampling and dosing system. Two remote I/O stations were set up separately, responsible for data acquisition from units #1 and #2 and units #3 and #4. ControlNet communication modules were installed at each station and connected to the ControlNet network. The Logix5550 processor within the gateway completed data processing and control tasks. The ControlNet network completed network data exchange through the ControlNet module within the gateway, and then communicated with the Ethernet network through the Ethernet module. Sixth step: Network access for the second phase of the project (coal conveying system, water purification station system, circulating water pump room, industrial water pump room, fuel oil pump room, etc.). In selecting the configuration software, considering that each subsystem has been running for a long time and the operators are already familiar with the operating methods, making major modifications inconvenient, the configuration screens of each subsystem were retained. The monitoring system uses RSView32 with 32,000 points as the monitoring configuration software. The specific operation is as follows: For subsystems in the original system that use RsView32, the method is: use the database input/output wizard provided by the RsView32 tool to export the data tags from the subsystem's project file, carefully verify them, and then import them into our new project; for Display, Event, and Macro, the files in their corresponding project folders need to be copied into our new project, and then the project needs to be opened and imported separately. For subsystems whose configuration software is not RsView32 (such as Intouch), the method is: understand the original system screen structure, then use RsView32 to redesign the screen, establish the database, and recompile the command statements. The system monitoring screen adopts a hierarchical structure design, making it easy to switch between subsystems, intuitively reflecting the on-site working conditions, and easy for operators to use. Its greatest features are simplicity, intuitiveness, and complete functionality. The hierarchical structure facilitates accurate switching between multiple subsystems by operators, avoiding misoperations caused by a complex system structure. Each subsystem uses similar function menus, ensuring convenient switching and comprehensive functionality. Multiple operations can be performed within the same main screen, and all submenus are pop-up menus. The monitoring screen structure is shown in Figure 5. Each subsystem has sub-screens similar to those in the #1 and #2 carbonated water dosing subsystems, which are not listed individually in the structure diagram. [img=400,336]http://www.cechinamag.com/images/Article/4f716c00-1845-4bb6-8388-cb991cd9a3dd/15.gif[/img][align=center] Figure 5[/align] The monitoring system includes system screen generation, accident replay system, various curve displays and printing, and various report generation. The monitoring screens should conform to the design style of the power plant's main control DCS system human-machine interface, and be designed according to the principle of hierarchical browsing and progressive refinement. Various design methods conforming to Windows standards, such as pop-up windows and drop-down menus, should be used to achieve screen switching and display. The process flow, information display (including operating parameters, status, fault conditions, etc.), and various curves on individual screens should be logically and vividly laid out with soft colors. The accident replay system includes all events entering the control system (such as parameters, feedback, etc.) as well as events occurring within the control system itself (such as card or communication failures, etc.). All I/O points can be displayed in curve form, providing rich data resources for online analysis and diagnosis of system operation.