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APCS of brewery boiler-room. LLC "Siberian Brewing Company" (“Krasnyj Vostok”), Novosibirsk

The APCS is implemented on the basis of DCS1 “Tornado-I” and designed to perform all remote monitoring and control functions of the electrified equipment of the boiler-room. The control objects are DE-25 boilers and general boiler part.


Stages of work

The creation of boiler’s APCS of CJSC “Siberian Brewing Company” began in late 2002, at the final stage of building of a brewery plant in Novosibirsk.

The general contractor of this project was CJSC “SibCOTES” company. The specialists of CJSC “Tornado Modular System” developed and supplied the DCS and performed a part of the designing and adjustment work.

Control system design and assembling and testing of the DCS were accomplished in four months. The main assembling and commissioning work of the system were completed in spring 2003.


The system features

The APCS on the basis of DCS “Tornado-I” is a modern development in the field of the complex automation of the boiler-rooms of various sizes and complexity. The system provides a modern management level of the boiler-room equipment in accordance with the criteria of economic efficiency, improves the quality of control and ensures economical fuel burning. The system implements full-scale monitoring and control functions of the boiler-room, extends capabilities of the operational staff by providing the stable operation of the equipment and increases the service life of the units. System reliability is ensured by the use of the modern architectural and design solutions and the reliable components, first of all, the controllers with high mean time between failures (MTBF).

The DCS “Tornado-I” was developed by Russian specialists who are familiar with specifics of the domestic control and measuring devices & automatic equipment (CMD&A), so all the main problems of compatibility between the system and the sensors of any calibration and various actuators were solved in the DCS.


The main functional capabilities of the system

The system allows implementing the following functions:

  • Displaying on the computer screen the state of the boilers and general boiler equipment with different detail level.
  • Management of the boiler-room objects in all operational modes including start and shutdown.
  • Control of the technological parameters in a given mode.
  • Remote control of all the electrified equipment of the boiler-room.
  • Technological protection and locking.
  • Automatic control and continuous diagnostics of the sensors and the DCS equipment.
  • Monitoring of commands execution.
  • Differentiated access to certain operations for operators, the system protection from accidental or unauthorized actions.
  • Logging of operator’s actions.
  • Alarm (including the sound alarm).
  • Formation of the database with original and calculation data.
  • Archiving all the technological parameters, actions of the staff that controls the boiler-room equipment and unauthorized accesses to the control system.
  • Solving the data tasks (calculation of technical & economic indexes of the equipment operation, registration of the deviation of parameters and other routine problems).
  • Creation of printable reports.


The created APCS is scalable, so in the future the system can be expanded with additional operator’s AWSs and also with workplaces without control functions, operating in the “view only” mode (for the administrative staff of the boiler-room).


Controllers

The controllers of the general boiler-room equipment and the controllers of the boiler management (one controller cabinet for each boiler) belong to the lower level of the system.

Each controller is a stand-alone device and can provide control of the facility in the absence of communication with the operator, thus avoiding failures in case of the upper level or network connection malfunction. Controllers are mounted in one-sided servicing cabinets of IP55 level of protection.

Use of the standard design elements and modern engineering technologies allows creating intuitive, aesthetic and easy to maintain controller cabinets. Well thought out design of the cabinets allows, in particular, avoiding the use of the cumbersome cross-cabinets, relay cabinets and transformer panels as well as reduce the amount of used cable which simplifies assembling and maintenance of the cabinets and significantly reduces the price of the system.


The following components are installed in each cabinet:

A controller crate with IUC-32 processor module manufactured by “Kontron” (“PEP Modular Computers”), Germany. These modules have a high speed, sufficient to implement all control algorithms of the boiler. The controllers have high performance specifications and long MTBF.

The I/O modules manufactured by “Tornado Modular Systems”. The mezzanine modules that are made in ModPack international standard are used. A wide choice of the available expansion modules allows solving any tasks of data collection and processing in the boiler-room.

The power sources and batteries manufactured by “Tornado Modular Systems” and partners.

The Field Interface Units (FIUs) manufactured by “Tornado Modular Systems”, providing direct connection of the controller to the equipment of the facility, sensors and actuators, bypassing the converters. The FIUs allow connecting the correct signals from the thermocouples, resistance temperature detectors, current and voltage sensors as well as discrete signals and commands of 24 V and 220 V.

Controller cabinets have the following characteristics:

  • power consumption for each controller cabinet is less than 75 W;
  • absence of forced cooling (the special cooling tools for the controller cabinet equipment are not required, which increases reliability and durability of this equipment);
  • temperature operation range of controllers is from 0 to +55 ° C.

Assembling of the controller cabinets is executed in a short time and does not require special industrial environment or equipment.


Computer workstations (AWSs) and servers

AWSs of the boiler-room process control operators, APCS engineer’s station and servers of databases and applications are related to the upper level of the system. The operator’s and engineer’s AWSs are equipped with modern standard tools of computer equipment compatible with IBM PC with 21’’ monitors with a “mouse” manipulator and a keyboard. The functionality of each station is determined by access rights.


Boiler-room operator’s AWS

The AWS allows interaction between operator and the APCS, provides alarms about deviations of parameters, allows issuing commands about management of technological process by process control operator, registers information necessary for further analysis in the retrospective view mode and allows printing the necessary information.

The “InTouch” is used to create an operator’s interface. This is a specialized software package manufactured by “Wonderware” company (Russian version) for monitoring and control of technological processes.

The operator’s interface is organized in the form of graphic elements of different level of detail, which reflect current state of the facilities of the boiler-room and provides effective control of these facilities.

There are several types of mimic diagrams in the process control operator’s interface: symbolic circuits with different level of detail, graphics, histograms, tables, protocols, reports.

The symbolic circuits form a “tree”, which is called through menu. A part of the calling menu of the mimic diagrams is constantly located on the screen. Some mimic diagrams are automatically closed to reduce probability of wrongful pressing of important buttons. In case of alarming deviations of the parameters they can be quickly found by pressing of a single button.


APCS engineer’s AWS

The engineer’s AWS is designed for implementing the following functions:

  • configuration of parameters and structure of the DCS;
  • restoring the system after emergency;
  • diagnostics and testing of the DCS;
  • conducting the scheduled operations;
  • creating the software and database backups;
  • generation of reports about the course of the technological process;
  • making changes in the technological controller’s and visualization software;
  • metrological calibration of measuring channels.

The engineer’s AWS is a “hot” reserve in case of failure of a process control operator’s workplace.


1 Distributed control system. 



 

 


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