Automation systems

General specifications

The automation systems are intended for:

  • automation of technological lines, sections or workshop;
  • technological process control and diagnostics;
  • generation and import of reports and archive documentation.

The automation systems provide for:

  • high information capacity, helping to assess the state of the process;
  • quick analysis of technological situation and breakdowns in the technological process;
  • high accuracy of control over the production process technological parameters;
  • maintenance of technological mode as per specified algorithm;
  • expandability of the automation system in case of further development of production.

Applications

  • Automation in metal industry – monitoring and control of rolling mills (slabbing mill, speed range control, 4-stand mill), cut-to-length system;
  • Automation of electrolysis and graphitization processes – remote control and equipment control;
  • Supercharger control automation – equipment condition monitoring, gate valves operation;
  • Start-up automation for pumps, fans by means of soft starters;
  • Equipment condition diagnostics.

Design

  • Structurally, the system may have the following versions, depending on the nature and scope of the task:
    – Desktop version – for installation on the duty officer workplace;
    – Panel – for incorporation into existing structures;
    – Console – for location on the operator workplace;
    – Cabinet – for autonomous non-supervised operation.

The system can consist of both one constructive module, and several spatially distributed modules in the turbine building or workshop. 

Architecture

 The development of spatially distributed automated systems for collection and processing of data and technological processes control demands tailored solutions for building data transmission networks.

Automated Process Control System (APCS) follows a hierarchical principle and has a multi-level structure.

The following levels of hierarchy are distinguished in the APCS:

  • low level – the level of sensors and actuators;
  • middle level – the level of industrial controllers (PLC);
  • top level – the level of industrial server and network equipment.

The low level consists of sensors and actuators installed on technological objects. The connection of sensors and actuators with middle level is ensured using radial and network connections.

The middle level consists of industrial controllers, power automation, signalling automation and necessary secondary devices.

Industrial logic controllers perform:

  • collection and processing of data from sensors;
  • monitoring and control of technological objects as per specified operation algorithms.

Data transfer and receipt of control commands from the middle level to the top level is carried out using standard industrial interfaces.

The system’s top level consists of operator’s and dispatcher’s Automated Workstations, industrial server and network equipment installed in various rooms and buildings.

Network equipment consists of hubs, switches and converters.

Functional specifications

  • automatic dispatching of technological equipment parameters (rolling speed, maintenance of set values for all basic technological parameters, pressure levels, temperatures and consumption rates of technological devices);
  • comparison of measured values ​​of technological parameters with set values ​​and generation of control signals,
  • generation of warning and alarm signals;
  • display of process flow in a form of mnemonic diagrams, trends (graphs of parameters changes over time), indicators;
  • chronometration of main technological parameters, generation of event log and historical data;
  • automatic and manual control of switching equipment, electric bolts and adjustment valves;
  • process archiving;
  • integrated management of all equipment items involved in the process;
  • implementation of required process control algorithms of any logical and mathematical complexity;
  • integration into the existing APCS network of enterprise;
  • graphic display of the process parameters and equipment in order to allow the staff to analyze compliance of the process to the required standards, distribution of loads on equipment, control of permissible loads upon the mechanical part of equipment;
  • oscillography of equipment parameters;
  • protection of process equipment;
  • logging of operator’s actions;
  • protection against incorrect actions of operator;
  • work with industrial fieldbuses: Modbus RTU, Modbus TCP / IP, Profibus DP, Profinet, CANopen, etc.;
  • possible adjustment of the automation and display structure and algorithms by the customer’s staff in the course of operation.

Hardware

  • The automation system represents a programmable logic controller of the following series: S7-300, S7-400, S7-1200, S7-1500 (SIEMENS), M241, LMC058, M340 (SCHNEIDER ELECTRIC). All systems can use remote input/output devices.
  • For process visualization the following is used: graphic panels (SIEMENS, SCHNEIDER ELECTRIC, WEINTEK), industrial computers (SIEMENS, ADVANTECH, AXIOMTEK), office personal computers, servers.

Software

The software in the software and hardware complex is intended for implementation of automated control for process equipment and scheduling of process parameters in APCS.

The supplied software can be easily integrated with the company’s automated process control systems and other automation systems existing in the company due to application of standardized solutions.

  • Software implementation for PLC on STEP7, SoMachine in languages ​​LAD, FBD, STL.
  • SCADA systems used for visualization – WinCC (SIEMENS), InTouch (WONDERWARE).

 

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