• 04 july 2017
    At the Technoprom Forum, an agreement was signed between "Tornado Modular Systems" with "Siblitmash" and "Komintern"

    The tripartite agreement provides for import substitution for components of the injection molding complex from SibLitMach in the field of industrial robots ("Comintern") and the control system ("Modular Tornado Systems") that will cover the entire production cycle of the LAP, including the management of industrial robots

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APCS of the TPE-430 boiler unit

The APCS is based on DCS “Tornado-M” and designed to perform full-scale control functions of technological processes of the boiler unit in all operating conditions, including start-up and shutdown. There are more than 1000 channels of monitoring and control in the system.

“...Start-up of the boiler unit with the first full-scale APCS for the station in this short time was executed due to the fact that distributed control system is supplied almost ready for work, design is carried out quickly, correctly and at the high technical level. Accuracy of the work and commitment of CJSC “Tornado Modular Systems” team to the stipulated dates became the basis for our further team-work over the APCS implementation at the next boiler unit of the station” 

Evgeny Alexandrovich Anisimov
Chief Engineer of Biysk CCHP-1.
20 February, 2003.

biysk5.jpgThe APCS is based on DCS “Tornado-M” (Russian GOST license of Tornado No. POCC RU.ME24 / B00475) and intended for automation of the technological process control on the boiler unit in all operating conditions, including its start-up and shutdown. Automation covers the full set of the monitoring and control functions.

The DCS is a central part of the system. Sensors, actuators, traditional control tools and non-programmable automation tools (which are supplied with the technological equipment) and power assemblies of gates of RTZO type (which are supplied by the manufacturer) are also included in the system.

Technological object

biysk6.jpgControl object: a steam boiler of E-500-13,8-560KT type (a TPE-430 / A model) manufactured by Taganrog manufacturing group “Krasny kotelshchik”.

  • main fuel: coal;
  • burners: 8 pcs;
  • fuel oil injectors: 8 pcs;
  • pulverized-coal system with holding bin: 2;
  • exhausters: 2;
  • blower fans: 2;
  • boiler capacity: 500 t/h;
  • P: 140 kgf/cm2;
  • steam temperature: 560 degrees;
  • isolation and control valves: 120;
  • auxiliary devices: 30.

Work stages

The main purpose of the APCS creation was to improve reliability and technical, economical and ecological indices of the boiler unit, as well as operating conditions for the operational staff and staff training. The work included the following steps:

  • Development of technical assignment for APCS. Development of project design and operating documentation for the system.
  • Assembling & commissioning of the DCS on the Customer's site.
  • Complex assembling & commissioning of the system to the trial operation, starting-up & adjustment of the electrical equipment.
  • Customer’s staff training, DCS after-sales service.
Assembling of the APCS cabinets

biysk7.jpgThe works were carried out by CJSC “Tornado Modular Systems” together with CJSC “SibCOTES” technological organization and “TEP” Novosibirsk Institute. A part of the adjustment works was executed by OJSC “Sibregionstroy” Construction Company. The contract between the “Tornado Modular Systems” company and LLC “Biyskenergo” was signed on June 6, 2002. Technical assignment was approved on 5 July. System design, equipment package, assembly and testing of DCS were executed within three months.

In late September, the integration test of DCS “Tornado-M” was carried out in presence of the Customer on the “Tornado Modular Systems” site, where the system functionality was tested using software emulators of technological equipment. On October 13, the DCS was delivered to the station. On November 14, the boiler was kindled, after main setup and adjustment works and additional training of the staff. On February 12, the system was commissioned to the trial operation.


In the process of system creation special attention was given to the training of the station staff. Training was conducted in several stages and was executed by specialists of CJSC “Tornado Modular Systems” and CJSC "SibCOTES".

The first stage included the preparation of the operational and administrative staff for energy equipment control via the DCS.

The second training stage was a part of the DCS integration test and conducted at Training Center of the CJSC “Tornado Modular Systems”. At this stage, the station staff was acquainted with the hardware and software components of the system, connection schemes and power supply organization. The audience participated in the DCS testing and carrying out metrological calibration of the measurement modules of the system.

The third stage was conducted at the station at the time of the system adjustment and included training on modification and development of the system. In addition, the station staff together with the specialists of “Modular Systems Tornado” executed the system adjustment.

Thus, the training was conducted at all of the project stages, which allowed the station staff to participate directly in the system creation.

General principles of the APCS integration

The APCS has a division, which considers the specifics of the technological process of a control object. The boiler unit can be conventionally divided into functional units, which are characterized by relative autonomy of technological tasks performed by them. The structure of the control algorithms, as well as mimic diagrams of the screen images considers distinction of the functional units. This creates a modular system structure with good comprehension of hardware, control algorithms and means of communication between the staff and the system. This also simplifies adjustment, understanding of the system by the staff and subsequent operation.

Structure of the APCS

biysk.jpgThe system complex is built according to the traditional hierarchical scheme. The upper level of the system provides interaction of the process control operators and engineering staff with the controlled technological equipment of the boiler unit, organizes a work of the system and preparation of data arrays for its use by the non-operational administrative & technical station staff. The upper level is represented by automated workstations (AWSs) of a process control operator, the APCS engineer and servers.

The lower level performs collection, input and processing of analog and discrete data of the DCS, forms and processes discrete control actions at the units and also performs regulation according to various algorithms and performs protection tasks. It includes the controllers connected by the duplicated Ethernet network, as well as auxiliary equipment, which provides the intermediate amplification of signals and other auxiliary functions. In addition, the lower level performs certain functions of protection and automatic control when communication with the upper level is not working. The computers of the upper level and the controllers are connected by the duplicated Ethernet network.

Besides the main system there is the non-programmable duplicated system. The duplicated system is designed for fail-safe shutdown of the boiler in case of the APCS failure.

Automated workstations (AWSs)

The computer workstation (AWS) of process control operators is located in the operational circuit of a group control desk. The AWS is designed for: visualization of the technological process parameters, remote control of the actuators, input of tasks for the regulators, review of individual protocols, reports and summaries, switching on or switching off of the control subsystems (autocontrol, automatic load transfer, functional & group control, etc.).

The “InTouch” software package manufactured by “Wonderware” company is used as a graphical user interface.

The AWS of the APCS engineer is located in the non-operational circuit of the group control desk and designed for the DCS service. The AWS can be used to perform such tasks as diagnostics of the DCS hardware, data archiving on long-term storage mediums, collection and review of reports and summaries, modification of algorithm parameters in the controllers and others. In addition, a software design package is installed on the engineer’s AWS, which allows the engineering staff (with the appropriate access) to modify the software of upper and lower system levels.

Besides, a set of programs for the metrological system support (the software for the metrologist’s AWS) is installed on the engineer’s AWS.

Controllers of functional units (CFUs)

biysk1.jpgThe APCS lower level is based on the CFU1 cabinets with installed technological controllers. The dual access cabinets of the IP55 level of protection from external factors has been used.

The main element of the controllers are modules of intelligent functions (MIF) manufactured by “Tornado Modular Systems”, specialized for automation tasks of large objects of the heat-and-power engineering. The “hot swap” of modules without power shutdown of the controller has been implemented. The ModPack functional submodules are used as the remote terminal unit (RTU). A wide range of these modules allows solving all management tasks of the boiler units.

CFUs were placed in a special room, located beside the boiler in the B row at mark of 10 meters between rows of assemblies of RTZO cabinets. This arrangement considerably economized the length of cable trends and increased fire safety at the object.

The Customer also made request to use the available non-shielded aluminum cables. Due to the high metrological characteristics and interference immunity of measuring modules of the DCS “Tornado” usage of these cables was approved. Experience of the system operation at the boiler No. 16 has confirmed the possibility of using this cables with the DCS “Tornado”.

1 Controller of functional units.



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