• 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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The APCS is based on DCS1 “Tornado-M” and designed for full-scale control of the equipment of the 200MW power-generating unit No. 6.

tec5_6_7.jpg“This is a unique start-up in the history of today’s Russia. It took just the shortest time to complete the technological works of unprecedented scope for the country and quality that the West could only dream about. The whole project was performed by virtue of joint financing by the stockholders and rational pricing policy supported by the local administration”. 

K.K. Gibert.
Director General of OJSC “Novosibirskenergo”.
September 2004.

Technological objects

The automation object is the TPP power-generating unit of 200 MW capacity including the following components:

  • Boiler unit (steam generator) of EP-670-3,8-545 KT drum type (TPE - 214/B model) manufactured by “Krasny Kotelshchik” plant, Taganrog; nominal capacity of the boiler unit is 670 t / h.
  • Heating steam turbine of T-180 / 210-130-1 type, designed for direct drive of the generator of TVG-200M-2PUZ type manufactured by “Electrotyazhmash” Kharkov plant, mounted on foundation along with the turbine and for the heat supply for delivery water heat up (main parameters: nominal capacity: 180 MW; nominal heat load: 260 Gcal / h; maximum capacity: 210 MW).
  • All work on this project was carried out by the leading technological and design organizations: “Tornado Modular Systems”, CJSC “SibCOTES”, CJSC Novosibirskenergo “Engineering Center”, CJSC “NovosibirskTeploElectroProekt”.


About the project

tec5_6_1.jpgAPCS of the power-generating unit is based on DCS “Tornado-M” specifically created to solve the tasks of automation of the large power engineering facilities considering the peculiarities of these objects and their high requirements to reliability and response time.

The control system of the power-generating unit is based on a modern microprocessor-based DCS “Tornado”, which provides high reliability and availability of the system in all modes, including start-ups, scheduled and emergency shutdowns in various thermal conditions of the technological equipment.

The peculiarity of the APCS designed and implemented at the power-generating unit is that the automation covers not only thermotechnical but also all electrotechnical equipment of the power-generating unit, while all control, information and service functions required for fail-safe operation of the object are performed in full.

The total scope of the system is about 7000 channels.

Structure and composition of the APCS

APCS of the power-generating unit based on DCS “Tornado-M” has functionally and territorially distributed architecture. The DCS of the system is built according to the conventional two-level hierarchy.


tec5_6_5.jpgCollection, input and processing of analog and discrete information of the DCS, formation and testing of discrete control actions (including software-based ones) on the units and control based on the desired laws are performed by the lower level components.

The DCS “Tornado-M” lower level is based on the new series of MIF-controllers equipped with MIF-PPC communication modules based on a superscalar RISC processor PowerPC. This processor has a high performance of 100 MIPS and an integrated communication PowerQUICC coprocessor. The processor of MPC860TZP80D4 module has improved capabilities of data processing and speed characteristics. The FastEthernet Integrated controller (Ethernet-100) allows maintaining 100Mbit connection of the DCS at any network load with an arbitrary number of switched channels.

The controllers of the functional units (CFUs) (which are the basis of the lower level) are installed in the double-side cabinets (800x800x2000 mm dimension) and connected by the Ethernet-100 duplicated network, common for upper and lower levels of the DCS.

tec5_6_3.jpgAll technological information of electrical and thermal power equipment is transferred via standard interface channels directly to the controller cabinets without use of the cabinets or intermediate terminal blocks.

Sixteen controllers of the functional units (CFUs) are included in the APCS DCS lower level. These CFUs are located in twenty-seven cabinets of the IP55 level of protection from external actions. Removable remote terminal units (RTUs) in cabinets of the IP55 level of protection are also included in the APCS DCS lower level.

The cabinets are located in the non-operational circuit of a facility control desk, at mark of the turbine maintenance (row A), in the room of the converting substation of electrofilters. The RTU cabinets are located at the +56 mark of the upper area level of the boiler unit for input of signals directly from the thermocouples.

The DCS upper level of the main system provides interaction of the process control operators and engineering staff with controlled technological equipment, organization of the system operation at the power-generating unit and the system connection with the plantwide level.

The DCS upper level consists of the hardware connected by the duplicated Ethernet network:

  • three operator stations, which form six-monitor automated workstation (AWS) of an operator;
  • dual-monitor operator station of a senior operator;
  • operator station of the staff, who tend the APCS;
  • engineering station of the field engineers;
  • engineering design station;
  • duplicated database server;
  • duplicated application server;
  • auxiliary server, servicing of A3 and A4 printers, it also performs the function of a bridge to the plantwide network;
  • operator station of a chemistry analyst is located in the express-laboratory and connected with the other hardware by the non-duplicated Ethernet network;
  • workstation of a metrologist-heating engineer is connected to the non-duplicated plantwide Ethernet network;
  • combined workstation of a metrologist-electrician and RPAE2 engineer are connected to the plantwide Ethernet network.
tec5_6_6.jpgEach AWS is equipped with specialized software & hardware, optimized for the assigned tasks. Optical fiber and twisted-pair cable of industrial design are used as a data transfer medium; the Ethernet network topology of the control system is duplicated and radial.

DCS “Tornado” is an open system, which allowed integration of the equipment by other manufacturers into the APCS of the power-generating unit No. 6. The following equipment:

  • the local monitoring system of microprocessor-based protection of the generator-transformator unit, based on the RMA3 “EKRA” equipment;
  • the monitoring station of excitation system of the generator based on the equipment of “Energocvetmet” company;
  • the microprocessor-based terminals of electrical protections of 6 kV distribution equipment manufactured by “Mehanotronika”;
  • subsystem for pyrometric control of the torch in the boiler furnace.
In addition to the duplication and backup of composite components of the main system there is external backup performed by creating a separate and independent reserve control system. In case of failure of the main control system, the reserve system provides fail-safe shutdown of the power-generating unit. It’s based on the non-programmable tools and arranged in the form of local devices and control keys, which are located on the panels of the operational circuit of the facility control desk.

1 Distributed control system.

2 Relay protection & automatic equipment.

3 Research & manufacturing association.



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